Rösler Oberflächentechnik: ‘Hidden Champion’ from Upper Franconia

High-precision and efficient surface treatment processes play a key role in die casting. One of the top addresses for these technologies is Rösler Oberflächentechnik GmbH, a family-owned company with over 80 years of experience and a global reach. As the world market leader in mass finishing and shot blasting technology, Rösler sets standards. Headquartered in Upper Franconia, the company employs around 1,600 people at 15 locations worldwide.

Rösler Company building/ Rösler Oberflächentechnik — Rösler company building at the Untermerzbach site

Gardena shear blade / Rösler Oberflächentechnik — Shear blades from Gardena - before and after surface treatment

What makes Rösler special is not only reflected in the large number of industries that the company supplies, but also in the direct presence of its technology in everyday life. It is estimated that every person in Germany holds an object that has been processed using a Rösler system in their hand twice a day. This ranges from the housing of a smartphone, whose aluminium edge has been deburred by vibratory finishing, to the polished blades of Gardena garden shears and coins that are blasted during the manufacturing process. Many customers rely on Rösler's technology without making this public so as not to allow any conclusions to be drawn about their production and machining processes. Discretion is just as much a part of Rösler's corporate philosophy as technological precision.

Rösler processes and systems are also used in sensitive areas such as medical technology or aerospace.

‘We process almost anything made of metal, from small connectors or knee implants to aircraft fuselage components or turbine blades,’ says Stephan Rösler, who is the third-generation managing partner of the company.

‘We also offer special processes for wood, ceramic and stone processing.’

From porcelain manufacturer to plant manufacturer

The origins of the company date back to 1933, when Richard Stephan Rösler founded a porcelain company in Desná, as Dessendorf in the former Sudetenland is known today. After the Second World War, a new start was made in the Franconian town of Tettau-Schauberg, initially with ceramic closures for beer bottles and pharmaceutical porcelain, followed by expansion to Bad Staffelstein and Untermerzbach. The transition to surface technology began with the development of ceramic abrasives - initially from the fragments of the company's own porcelain production. From these beginnings, a highly specialised mechanical engineering company developed, which today is represented in almost all industrial sectors.

‘We have reinvented ourselves several times over the course of our company's history,’ explains Stephan Rösler. ‘Today, we not only supply machines, but also complete solutions that set standards worldwide - in the foundry industry as well as in medical technology, the automotive industry, aviation and many other sectors.’

A technological milestone was the entry into blasting technology in the 1990s. With the establishment of the AM Solutions brand in 2018, a separate business division was created for the post-processing of additively manufactured components - a future field that is also becoming increasingly important in the foundry industry.

Stephan Rösler / Rösler Oberflächentechnik — Managing partner Stephan Rösler is the third generation to run the company

Die casting: solutions for aluminium, zinc and magnesium

The die casting and foundry industry is one of the most important customer segments. According to the company, around a third of new machine business in the blasting technology sector is attributable to this industry. ‘Our technologies enable cast components to be deburred, descaled or specifically hardened economically and efficiently,’ says Stephan Rösler.

Whether aluminium, zinc or magnesium - Rösler offers tailor-made solutions: high-performance system technology, individually formulated abrasive media and compounds as well as a deep understanding of the process. A typical example is the shot peening process, which is used by BMW, among others, for transmission parts in electric cars. In this process, the surface is made more resilient through targeted hardening with round abrasives - a decisive advantage in lightweight construction.

‘In our view, it is the interplay of numerous factors that makes us the global market leader in the field of mass finishing and shot blasting technology with our complete package,’ explains Stephan Rösler.

‘Firstly, our comprehensive product portfolio: Unlike many other companies in the industry, we have not specialised in one processing technology, but offer shot blasting technology and mass finishing technology on an equal footing.‘

Gardena shear blade factory with various machines and many pallets of ceramic grinding wheels — A look at ceramic grinding media production

Technological ecosystem from a single source

In fact, Rösler offers everything from a single source: from planning and design to production and installation to commissioning and maintenance. The product spectrum ranges from circular vibrators, continuous systems and wire belt blasting systems to fully automated lines with robotics and digital process monitoring. In addition, Rösler develops all process media itself - over 15,000 variants of abrasives, blasting media and compounds are available. This means that the company has the world's largest portfolio in this area.

This combination of broad technological expertise and vertical integration is one of the reasons for the company's sustained success. With its own development centre for additive manufacturing, a new laser bending system for steel construction, an in-house energy centre and an AutoStore for small parts picking, Rösler has recently made further investments in Germany.

‘Best of German Industry’ award
Rösler is also setting standards in the area of sustainability: A new generation of kilns that use less energy, photovoltaic systems and an in-house energy centre are examples of this. Sustainability is not only an internal claim, but also a sales argument, as energy-efficient machines reduce customers' operating costs.
Rösler 2024 was honoured with the ‘Best of German Industry’ award for this overall picture. The jury not only recognised the company's technological breadth, but also its role as a ‘hidden champion’, whose innovative strength and stability make it one of the backbones of German industry. Stephan Rösler also sees the award as confirmation of the company's long-term approach:

‘We continuously invest in research, development and training because we firmly believe that sustainable success is based on knowledge, experience and trust.’

Knowledge as a value: The Rösler Academy

With the Rösler Academy, the company has created a training centre that is also open to external customers. Fundamentals and specialised knowledge of mass finishing and blasting processes are taught in practical training courses. The seminars are aimed at specialists, production managers and developers. In this way, Rösler not only ensures well-informed customers, but also strengthens process reliability when using its systems.

With over 1,000 employees in Germany and a global sales network of 150 national and international sales representatives, Rösler is now one of the most important suppliers in the surface treatment sector. In addition to its commercial success, the company is also active in specialised committees, such as the EUROGUSS Executive Circle, which is committed to promoting innovation in the industry. The company remains an indispensable partner for the die casting industry.