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08.05.2026 | Press release
Modular TPE Bellows for Special-Purpose Vehicles and Industrial Applications
Weinheim, May 8, 2026. Freudenberg Sealing Technologies is expanding its portfolio of bellows with a new manufacturing process for small-batch production. For the first time, custom-designed bellows made of thermoplastic elastomer (TPE) can be produced with significantly reduced tooling and fixed costs. This is feasible due to a modular tooling concept developed specifically for application-specific bellows geometries in small quantities.
Bellows are used wherever moving machine components need to be reliably protected and lubricated. They perform key functions in sealing piston rods, guides, valves, joints, as well as shafts and axles. Typical applications include agricultural and construction machinery, automation technology, fluid technology, power tools, and equipment in the pharmaceutical and food industries. In all these applications, lubricants must be securely retained within the system while simultaneously protecting sensitive components from dirt, moisture, and mechanical stress over the long term.
Proven standard range of rubber and TPE as a high-performance material alternative
Freudenberg Sealing Technologies offers one of the world’s most comprehensive stock programs for single- and multi-pleat bellows made of elastomers. With over 400 items, the range covers a wide variety of industrial requirements and is aimed at both original equipment manufacturers (OEMs) and the aftermarket. For many applications, these rubber bellows represent a cost-effective and proven standard solution.
Now, thermoplastic elastomers (TPE) open up additional possibilities for special applications and custom geometries. TPEs are characterized by excellent mechanical properties, a long service life, and high abrasion resistance. They can be used in a wide temperature range from –40 °C to +140 °C, offer high ozone resistance, and exhibit excellent resistance to oils and greases. This combination makes TPE particularly attractive for demanding industrial applications with increased requirements for durability and media resistance.
Modular tooling concept for small lot sizes
The key advantage of the new manufacturing process is its modular tooling concept. Rather than producing an entirely new tool, the bellows design is assembled individually from an existing modular system. This means customers benefit not only from the use of high-quality TPE material, but also from significantly lower tooling costs—making a cost-effective production of small batch sizes possible for the first time. As a result, custom bellows can be produced quickly, consistently, and cost-effectively.
Application example: Axle boot for construction vehicles
A typical application could be high-performance construction vehicles, which are often developed and produced in small batches. Their drivetrain must function reliably under extreme conditions—especially in all-wheel-drive vehicles used off-road. In this specific example, the application involves a drive shaft for a three-way tipper with a shaft length of 1,610 mm. The bellows required for this purpose do not correspond to any standard boot available on the market. The requirement is for an axle boot with nine folds, a maximum diameter of over 130 millimeters, and a total length of approximately 120 millimeters. The client initially orders bellows for the production of five all-wheel-drive prototypes intended for operation on difficult terrain. Following a successful evaluation phase, the three-way dump trucks are to be produced in series. Production of the drive shafts can be ramped up quickly for this purpose. At the same time, Freudenberg Sealing Technologies can deliver the bellows required for the drive shafts promptly and in line with demand, thanks to the tooling components already on hand.
Custom work with planning reliability
Especially in highly stressed joints, precisely designed bellows reliably prevent the leakage of lubricants and protect the mechanical components from weather conditions, dirt, and splashing water. While custom sizes were often not cost-effective in the past due to high tooling costs, the new concept enables reproducible sealing quality without compromising on robustness, service life, and fit accuracy.
Rainer Knorr, Manager of R&D and Product Management at Freudenberg Sealing Technologies, says: “We are gradually expanding our portfolio of bellows modules for the custom manufacturing of TPE bellows for general industry. This creates a modular system that allows to implement such projects faster and more cost-effectively in the future.” For customers, this means that once validated, designs can be flexibly adapted and reliably produced even in varying quantities.
Isolde Grabenauer
Senior Director Communications & PR
Telephone: +49 (0) 6201 960 7467
Contact via MailNews Service
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