BOSAL

Belgium

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BOSAL is a global manufacturer of automotive and industrial energy equipment founded in 1923. Headquartered in Lummen, Belgium, where its global management and main Research & Development Centre are located, the family-owned group employs over 2,500 people across manufacturing plants, distribution hubs, and technical facilities worldwide.

Bosal operates specialized business divisions spanning Powertrain (emission control, silencers, and exhaust piping), Chassis, and Energy Conversion. Its R&D center in Lummen employs advanced CAD/CAE numerical simulation tools and testing infrastructure to develop high-temperature energy systems and complex formed tubular and sheet components.

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Bosal utilizes hydroforming processes for both energy conversion systems and automotive exhaust manufacturing:

Foil Hydroforming: Patented hydroforming technique used to produce stress-free, corrugated ultra-thin metal foils of uniform thickness for advanced compact heat exchangers and recuperators.
Thin Foil Heat Exchangers: Laser-welded heat recovery modules (outputs 1 kW to 250 kWe) engineered for operating temperatures up to 1,000°C and pressures up to 60 bar, designed for Solid Oxide Fuel Cells (SOFC), Solid Oxide Electrolyzers (SOEC), and micro-gas turbines.
Tube Hydroforming & Forming: Tube hydroforming and automated forming used in the fabrication of exhaust pipes, catalytic converters, and silencer assemblies.
Materials Handled: High-temperature stainless steels, Inconel alloys, aluminized steel, and specialty thin metal foils.
Engineering & Validation: CAE process simulation, computer fluid dynamics (CFD), prototype laser welding, thermal cycling, and high-throughput durability testing.

BOSAL

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