Sheet metal components for commercial vehicles
Trucks and buses place different but equally demanding requirements on the sheet metal components used in them. In addition to design requirements, which play a central role in both sectors, the focus in freight transport is primarily on high mechanical and thermal stresses. In passenger transport, safety and structural stability determine the design.
Why Graepel is the right partner for commercial vehicle manufacturers
Graepel stands out as a development partner and series supplier for OEMs in the commercial vehicle sector thanks to its high level of manufacturing expertise in sheet metal processing and end-to-end process integration. From engineering through toolmaking, forming technology, stamping and joining processes to surface finishing, we produce durable, functionally integrated components from a single source. This enables weight-optimized yet high-strength components for demanding applications in truck and bus manufacturing.
A key factor is the ability to produce in industrial series while maintaining high flexibility in variants. Additionally, certified quality management systems such as DIN EN ISO 9001 and IATF 16949 ensure reproducible product quality and process reliability. These standards define internationally recognized requirements for quality management in series production and guarantee stable, audited processes throughout the entire supply chain.
Success Stories
Graepel has once again been certified to IATF 16949
At its Löningen facility, Graepel has once again successfully passed the IATF 16949 audit. This reaffirms the globally active manufacturer of sheet…
Graepel receives two supplier awards from PACCAR and its subsidiary DAF.
A strong signal for reliability and quality: Graepel was again honored with the Supplier Performance Award ‘Leader’ from DAF Trucks for the year 2024.…
Excellent performance: Graepel rises to “Leader” as a supplier at DAF.
Graepel, one of the world's leading manufacturers of high-quality sheet metal products, has received the Supplier Performance Award in the “Leader”…
Graepel’s new project with Iveco and Nikola
Graepel’s vehicle division is always growing. Now it has added electric trucks as well: Together with Iveco, development and production of battery…
“In the truck and bus industry, quality, process stability, and on-time delivery are critical. With IATF 16949-certified manufacturing facilities, we offer process-reliable solutions for dependable mass production—including just-in-sequence. Our components combine protective functionality, high dynamic load-bearing capacity, and first-class surface quality. From tooling to coated series products, we deliver everything from a single source.”
Marie-Christin Maier
CEO of Graepel GmbH & Graepel Süd GmbH
FAQ
Graepel DuraVent ventilation grilles offer the highest corrosion resistance for trucks and commercial vehicles, thanks to a precisely coordinated process that integrates coating, punching, and forming. In addition to very high corrosion resistance, airflow and air throughput are also optimized. Graepel DuraVent is one of the most cost-effective solutions for high corrosion protection requirements and typically meets corrosion protection classes C4–C5 according to DIN EN ISO 12944.
We manufacture aluminum step plates for trucks, tractor-trailers, and commercial vehicles—and can also produce them in stainless steel upon request. The aluminum alloys we use are EN AW-5754 and EN AW-6082, which offer an optimal combination of lightness, strength, and corrosion resistance. Surfaces are available anodized, brushed, or natural in various textures for increased slip resistance (R11/R13 per DIN 51130). Weight savings compared to steel step plates: typically 60–65%. Production from batch size 1 up to series quantities.
We manufacture ventilation grilles made of steel, stainless steel, and aluminum for trucks, buses, and commercial vehicles—from custom-made pieces to mass production. Our product range includes stamped perforated metal grilles with open areas of up to 80%. Finishes: galvanized, KTL + powder coating, anodized stainless steel, and other options available upon request. All parts are manufactured according to customer specifications and requirements. Delivery as individual parts or as fully coated assemblies.
Weight savings in truck tread plates can be achieved through three approaches: switching to aluminum, optimizing the geometry, and reducing wall thickness through the use of structural profiles. Aluminum tread plates (EN AW-5754/6082) weigh 60–65% less than comparable steel versions while maintaining application-specific load-bearing capacity. A perforated hole pattern instead of solid sheet metal saves additional weight. Profiles with stiffening ribs replace thicker flat sheets. Total weight savings compared to conventional steel step plates: up to 70% per unit. We would be happy to advise you on the optimal solution for your weight and load profile.
We manufacture brackets, beams, and mounting assemblies for radiator assemblies for trucks, commercial vehicles, and specialty vehicles—based on customer drawings or samples. Processes used: laser cutting, punching, bending, welding, thread forming, and surface treatment. Materials: steel, stainless steel, and aluminum. All welding work complies with DIN EN ISO 3834; coatings include KTL + powder coating or hot-dip galvanizing. Delivered as individual parts or as complete assemblies—ready for assembly and installation.
For ventilation grilles and metal components on trucks exposed to high levels of stone chip damage, we recommend KTL primer (cathodic dip coating) combined with an impact-resistant powder coating. KTL, as a base coat, adheres seamlessly even to edges and weld seams; the powder topcoat can be formulated with increased impact resistance (coating thickness 80–120 µm). For extreme conditions (underbody area, near wheel wells), a two-coat system consisting of KTL + textured powder is standard. Alternatively: Stone chip resistance testing according to DIN EN ISO 20567-1 available upon request.
We manufacture thermal insulation panels as visible components (A and B surfaces) for trucks and commercial vehicles with the highest aesthetic requirements—including smooth visible surfaces, a defined gloss level, and OEM-compliant color schemes (RAL/NCS). Dimensional accuracy and surface quality are tested according to customer-specific measurement specifications. Samples and PPAP documentation are available upon request.
For heat shield panels on trucks and commercial vehicles with elevated temperature requirements, we determine the appropriate coating system based on the load profile. For components located in the immediate vicinity of exhaust gases or near turbochargers, ceramic coatings or thermally sprayed aluminum oxide are standard. Temperature test certificates are available for all systems upon request.
A wide range of step plate variants can be produced at minimal tooling costs using adjustable stamping dies. Laser cutting allows for any geometric variation<s> </s>between variants—ideal for runs of 1–50 pieces per variant. For high-volume production, a stamping die pays for itself; thanks to a modular die design, multiple similar variants can be produced using a base die plus interchangeable inserts. We recommend starting with laser-cut samples for testing, followed by targeted tooling for the main variant. Tooling cost planning and batch size analysis available upon request.
