Hänssler
Contract manufacturing service providing large-format additive manufacturing (LFAM) for complex plastic parts up to 2.6m×1.7m, hybrid additive-subtractive processes, and sealing component production with 40 years of plastics and sealing expertise.
- CEO / Founder
- Rolf Hänssler
- Team Size
- 51-200
- Stage
- Active
- Total Funding
- Bootstrapped
- Latest Round
- Bootstrapped
- Key Investors
- None
Technology & Products
Key Products
Large-format additive manufacturing (LFAM) - FDM-based process for parts up to 2600×1700×950mm; Small-format FDM 3D printing (Ultimaker S5 platform); SLA stereolithography for precision parts; Mold and tooling production (LFAM-manufactured molds for injection molding); Sealing elements - piston seals, rod seals, O-rings, back-up rings, scrapers, guide rings, flat seals; Plastic construction parts - custom components from engineering thermoplastics; Hybrid manufacturing - additive+subtractive post-processing; Post-processing and finishing services for 3D-printed components
Technological Advantage
Proprietary LFAM hybrid process reduces mold manufacturing cost by ~50% and lead time from 8-12 weeks to 1-2 weeks; 60-80% material waste reduction vs conventional CNC methods; enables cost-effective medium-volume production (50-500 units) where injection molding ROI is marginal and CNC cost prohibitive; material flexibility (ABS, PC, PA6/PA12, PEEK, PPS, glass/carbon-reinforced variants) supports diverse applications; vertical integration of design, manufacturing, and finishing minimizes external dependencies.
Differentiation
Value Proposition
Reduces mold production lead time from weeks to days via LFAM; enables large complex geometries impossible with conventional machining; cuts material waste 60-80% vs traditional methods; hybrid process achieves high-precision tolerances (±0.3mm) on oversized components; one-piece production eliminates assembly; resource-efficient manufacturing for sustainability-conscious customers.
How They Differentiate
Hänssler differentiates via LFAM capability (large-format additive manufacturing) for custom parts where competitors use only traditional machining or injection molding; combines 40-year sealing expertise with cutting-edge 3D printing (hybrid approach); serves development-partner model with integrated design-to-manufacturing workflow; competitors are primarily sealing OEM suppliers, not solution-agnostic manufacturers. In LFAM space, competes with generalist AM service providers (HP, Stratasys, Velo3D facilities) but with superior sealing/precision engineering heritage.
Market & Competition
Target Customers
OEMs in aerospace, automotive, shipbuilding, wind energy, medical technology, and industrial sectors requiring custom plastic components and tooling
Industry Verticals
Aerospace; Automotive; Shipbuilding/Maritime; Wind Energy; Oil & Gas; Medical Technology; Food Industry; Plant Construction; Electronics; Mechanical Engineering
Competitors
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Growth & Milestones
Growth Metrics
40 years operational; ~65 employees; expanded into LFAM technology; TOP 100 Innovator award 2026; operating across 10+ industries; multiple international customers in aerospace, maritime, and industrial sectors.
Major Milestones
1986 - Founded as Hänssler Hydraulik GmbH by Andreas Hänssler and Reinhard Hänssler; ~1990s - Company name change to Hänssler Kunststoff- und Dichtungstechnik GmbH; 2000s - Rolf Hänssler (industrial engineer graduate, born 1981) joins family business; 2010s - Investment in Mazak Integrex for advanced CNC capabilities; 2020s - Introduction of large-format additive manufacturing (LFAM) technology; expansion into custom plastic parts and complex geometries; 2026 - Awarded TOP 100 Innovator Seal for LFAM technology and innovation culture
Notable Customers
HanseYachts AG (yacht interior panels, ammonia refueling systems for emissions-free maritime propulsion); Racing/motorsports teams (carbon-fiber reinforced mold production for performance components); Unnamed aerospace OEMs (structural component testing, tooling); Unnamed automotive suppliers (ESD-safe sealant components via Ultimaker partnership)