Milestone at BENSELER: 100 millionth injector body machined
Markgröningen, July 29, 2025
BENSELER recently electrochemically machined the 100 millionth injector body for Schaeffler's Vehicle Lifetime Solutions division. For more than 20 years, the company has been responsible for the ECM machining of components used in the common rail injection systems of various vehicle manufacturers. The non-contact process is used in particular where maximum precision is required: for the defined deburring of edges, the insertion of contours or the burr-free opening of bores.
"Cooperation over such a long period of time is a special sign of trust. This milestone is therefore an event that we are particularly pleased about," explains Silvio Peschke, Managing Director at BENSELER and responsible for the Deburring division. Every year, several million injector bodies pass through the automated ECM systems at the BENSELER site in Frankenberg. The process allows machining even in hard-to-reach areas without mechanical contact and without thermal stress on the workpiece.
BENSELER has been involved in the production of common rail technology since its beginnings - from simple injection systems to today's solutions. In the production process, the company is firmly integrated into the Schaeffler Vehicle Lifetime Solutions supply chain: The raw parts are taken directly from the machinist, stored and machined on call on the company's own ECM automatic systems. These are specially adapted by BENSELER to the customer's requirements. Packaging and dispatch follow at the end.
Contactless opening and deburring of bores
Just like injection technology, the electrochemical metalworking of injector bodies at BENSELER has evolved with the growing technical requirements. The deburring specialists can draw on more than 25 years of experience . Currently, injector body machining is carried out in three steps: a classic high-pressure water jet deburring process first preconditions the workpieces. This is followed by the burr-free opening of the bores. An electrochemical reaction gently removes the material until the borehole has the desired opening - completely free of burrs and chips. In the third step, the components are cleaned, checked and packaged. In 2024, the range of services was also expanded to include the electrochemical machining of nozzle bodies - another part of the common rail injection systems from Schaeffler Vehicle Lifetime Solutions.
Gentle and careful - even with hardened workpieces
"Deburring using the ECM process is ideal for rounding edges in precisely defined areas, especially in hard-to-reach places, with complex geometries or thin-walled and sensitive workpieces," explains Silvio Peschke. The material properties remain virtually unchanged and there are hardly any restrictions in terms of alloy or microstructure: BENSELER can deburr cast, pressed and forged parts with this method, as well as hardened workpieces.
About BENSELER
BENSELER is a competent service provider and partner for technically sophisticated solutions in the fields of coating, surface finishing, deburring and electrochemical metalworking of series parts. The BENSELER Group, based in Markgröningen near Stuttgart, consists of two divisions: Coatings and Deburring. In 2018, the company also entered additive manufacturing in the metal sector.
The company is constantly developing its core processes, supplementing them with upstream and downstream processes and maintaining system partnerships with its customers. BENSELER therefore understands the needs of the market and can offer solutions with added value. Several locations in Germany, the new subsidiary in Poland and holdings in Switzerland and the Czech Republic ensure proximity to the customer.
The BENSELER Group achieved a turnover of around 135 million euros in the 2024 financial year. It currently employs around 980 people, including 30 trainees. In addition to technical expertise, sustainability and social commitment characterize the actions of the family business, which has been in existence for more than 60 years.
