Custom grippers and fixtures: Special construction for every geometry
- Zeilhofer HHT
- 3 days ago
- 3 min read
Individual grippers andDevicesThese are the grippers that make standard manipulators suitable for demanding applications. While standard grippers move flat, simple components, complex geometries, sensitive surfaces, or confidential prototypes require custom-built solutions. Zeilhofer develops these precisely in Holzkirchen, from CAD design to preliminary acceptance testing.
Why individual grippers are necessary
Standard grippers with a flat suction plate or parallel clamping handle approximately 80 percent of all handling tasks. The remaining 20 percent require a different approach. Typical reasons for custom-built grippers include:
Complex 3D geometries with beads, undercuts or attachments.
Painted, polished or coated surfaces that cannot withstand pressure marks.
High load weights exceeding 800 kg, which overwhelm standard grippers.
Confidential prototypes with TISAX Level 2 requirements.
Hygiene-critical applications in the pharmaceutical, medical, or food industries.
From CAD to commissioning: the engineering process
A custom gripper is created through a structured engineering process. The starting point is CAD data or a 3D scan of the component. The key steps are:
Requirements specification: component, weight, surface finish, cycle time, safety level.
3D CAD design with collision analysis and motion simulation.
FEM calculation of load-bearing capacity and dynamic load.
Production takes place in our own factory in Holzkirchen, Germany.
Factory functional test with original or dummy component.
Preliminary inspection in the showroom or via video transmission.
Commissioning at the workplace and training of operators.
Gripper technologies for individual shots
Different gripper concepts are used depending on the component and process:
Vacuum suction cups with soft pads made of silicone, EPDM or foam for painted surfaces.
Clamping gripper with pneumatic spreading and defined force setting.
Magnetic gripper for ferromagnetic steel components.
Special mechanical fixtures with customer-specific geometry.
Hybrid combinations of multiple recording technologies.
Safety and certification
Individual grippers and fixtures are part of the machine and are delivered with CE conformity. Safety features such as pressure monitoring, redundant vacuum circuits, mechanical end-position locking, and Performance Level d safety technology according to EN ISO 13849 are standard, depending on the application.
For confidential prototype projects, we use our TISAX Level 2 prototype protection: NDA, documented access control, separate workspaces.
Application areas for grippers in special construction
Typical industries and applications for custom grippers:
Automotive: Doors, cockpits, body parts, high-voltage batteries.
Mechanical engineering: Large cast components, motors, axles, shafts.
Glass and PV industry: gentle handling of sensitive surfaces.
Pharmaceuticals and medicine: GMP-compliant stainless steel grippers for cleanrooms.
Defense technology: confidential prototypes with TISAX prototype protection.
Individual design from a single source
Engineering, design, manufacturing, pre-acceptance and commissioning all come from a single source in Holzkirchen.Zeilhofer Handling Technologyis ISO 9001 certified and operates according to TISAX Level 2 with prototype protection, with solutions for 18 industries and customers in over 50 countries.
Request special grippers
Do you need a custom gripper for a complex component? We analyze your geometry and develop a suitable gripper. Request a free quote now.
Frequently Asked Questions (FAQ)
What are individual grippers and devices?
Custom grippers and fixtures are customer-specific attachments designed precisely for component geometry, weight, surface finish, and process. Unlike standard grippers, they can also accommodate complex 3D geometries, delicate surfaces, and unusual requirements.
When does a custom-built gripper make sense?
When standard grippers cannot pick up the component safely or gently. Typical reasons include complex geometries, painted or polished surfaces, heavy weights, confidential prototypes, or hygiene-critical applications.
How is a custom-built gripper manufactured at Zeilhofer?
Based on CAD data or a 3D scan of the component, our engineers design a precisely fitting gripper in 3D CAD. This is followed by FEM calculations, manufacturing in Holzkirchen, factory functional testing, and preliminary acceptance testing with the original component before the device is delivered to the customer.
What gripper technologies are available?
Vacuum grippers with soft pads, clamping grippers with controlled spreading, magnetic grippers for steel parts, special mechanical fixtures, and hybrid combinations. The selection depends on component geometry, surface finish, and process environment.
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