Freudenberg Develops Modular TPE Bellows Production

Industrial equipment manufacturers increasingly require custom sealing components for low-volume machinery, prototype programs, and specialized drivetrain systems where standard parts are not suitable. In this context, Freudenberg Sealing Technologies introduced a modular manufacturing concept for thermoplastic elastomer bellows designed to reduce tooling costs and improve flexibility for small-batch production.

Bellows designed for demanding industrial environments
Bellows are used to protect moving mechanical components while retaining lubricants and preventing contamination from dirt, moisture, and mechanical stress. Typical applications include agricultural machinery, construction equipment, automation systems, fluid technology, power tools, and equipment used in pharmaceutical and food processing environments.

The components are commonly installed on piston rods, shafts, axles, joints, valves, and guide systems where long-term sealing performance is required under dynamic operating conditions.

Freudenberg Sealing Technologies already supplies a stock range of more than 400 elastomer bellows variants for OEM and aftermarket applications. The company’s portfolio includes both single- and multi-pleat designs intended for a wide range of industrial sealing requirements.

TPE materials expand custom design options
The new production concept focuses on thermoplastic elastomer materials as an alternative to conventional rubber bellows for specialized industrial applications and custom geometries.

According to the company, TPE materials used in the bellows provide operating temperature resistance from –40 °C to +140 °C, along with high abrasion resistance, ozone resistance, and compatibility with oils and greases. These material characteristics are relevant in drivetrain, automation, and industrial sealing applications where components are exposed to repeated movement, contamination, and lubricant contact over extended operating cycles.

The material combination is also intended to support longer service life and higher durability in environments with elevated mechanical and chemical stress.




Modular tooling reduces costs for low-volume production
The main technical change is the introduction of a modular tooling system for custom bellows manufacturing. Instead of producing a completely new tool for each geometry, the bellows design is assembled using pre-existing tooling modules.

This approach reduces fixed tooling costs and shortens setup times for small production runs. As a result, manufacturers can produce application-specific bellows in lower quantities without the tooling expenses typically associated with fully customized elastomer components.

Such modular manufacturing strategies are becoming increasingly relevant in flexible manufacturing environments where OEMs require low-volume production capability alongside rapid product iteration and shorter development cycles.

Construction vehicle drivetrain example
Freudenberg highlighted a potential application involving a drive shaft for a three-way tipper construction vehicle developed in limited quantities for off-road use.

The drivetrain application required a custom axle boot with nine folds, a diameter exceeding 130 mm, and a total length of approximately 120 mm for a 1,610 mm shaft assembly. Because the geometry did not match commercially available standard bellows, a custom design was required.

The example also reflects how low-volume industrial vehicle programs often transition from prototype builds to series production in stages. Using modular tooling components already available in-house allows production volumes to increase more quickly once the drivetrain configuration has been validated.

Repeatable sealing quality for custom geometries
The modular concept is intended to support repeatable manufacturing quality while maintaining sealing performance, dimensional fit, and durability in highly stressed mechanical joints.

Freudenberg Sealing Technologies stated that it is continuing to expand its library of modular bellows tooling elements for general industrial applications. The growing module portfolio is intended to allow future TPE bellows projects to be adapted and manufactured more quickly while maintaining production consistency across varying order volumes.

Edited by Aishwarya Mambet, Induportals Editor, with AI assistance.

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