24. March 2017

3D Sewing Robot

New Competence Centre Strengthens the "Composites” Unit

In 2015 PFAFF Industriesysteme und Maschinen GmbH and KSL Keilmann Sondermaschinenbau GmbH were merged. Business is done under the name of PFAFF Industriesysteme und Maschinen GmbH which combines the brands PFAFF INDUSTRIAL and KSL under one roof. In late 2015 the laboratory was established at KSL in Lorsch – a center of excellence that is unique in the industry.


The ksl laboratory serves as the interface between complex customer inquiries and sophisticated robot and CNC-technologies. Based on many years of experience and expertise, customer-oriented solutions and concepts are developed at the ksl laboratory. Feasibility studies are carried out, prototypes and small batches are realized and special sewing heads for systems are designed and assembled. In addition, new developments are completed and various KSL-machines and components are tested and optimized.


The LABORATORY-concept significantly enhances the vital areas of pre and after sales. Experienced technicians and engineers from IT, sewing technology CNC- and control engineering form the backbone of this new section. Currently, project machines for renowned customers from Europe, the US and Asia are designed at the LABORATORY and implemented in their production lines based on the customer requirements. In recent months, two new machines have been implemented for preforming large parts for the aerospace industry.


The Laboratory covers the following technologies:

Blind stitch

Two-needle sewing heads


Induction welding

Tape laying


Ultrasonic cutting

2D/3D CNC-sewing


Larger systems such as a portal sewing robot or a CNC-system that is 30 m long are assembled at the PFAFF INDUSTRIAL-facility in Kaiserslautern, since a bigger assembly area is available there. The subsequent area of application of both systems is fastening (along the Z-axis) large parts for the aircraft and space industries. The portal sewing robot works with a 1-thread chain stitch and is particularly suitable for three-dimensional parts; the CNC-system uses lockstitch to attach two-dimensional components (carbon fiber- and glass fiber).


Further information:

Johannes Dewald,
Global Sales Manager,
Pfaff Industriesysteme und Maschinen GmbH, Kaiserslautern,
phone +49 (0) 62 51 / 96 20-341,,