BIW Solutions Portfolio
Turnkey solutions for every aspect of body shop manufacturing – from automated production lines to specialized tooling systems
Automated & Semi-Automatic Production Lines
Complete body shop solutions engineered for maximum efficiency, flexibility, and quality output.
Fully Automated BIW Lines
State-of-the-art fully automated bodyshell production lines designed for high-volume manufacturing with minimal human intervention.
- Integrated robotic welding systems
- Automated material handling
- In-line quality monitoring
- Advanced process control
- Real-time production tracking
- Flexible model changeover capability
- Energy-efficient operations
- Industry 4.0 ready infrastructure
Semi-Automatic BIW Lines
Optimized balance of automation and manual operations, providing flexibility for mid-volume production and multiple model variants.
- Operator-assisted robotic cells
- Manual and automated stations
- Cost-effective implementation
- Easy reconfiguration for new models
- Scalable automation levels
- Ergonomic workstation design
- Quick changeover systems
- Training-friendly operations
Manual BIW Production Systems
Efficient manual production solutions ideal for low to medium volumes, prototype builds, and specialized manufacturing requirements.
- Ergonomic fixture design
- Manual welding stations
- Operator-friendly tooling
- Low capital investment
- Maximum flexibility
- Quick tool changes
- Ideal for prototyping
- Easy maintenance
Turnkey Line Implementation
We provide complete turnkey solutions from initial concept design through equipment installation, commissioning, and production ramp-up. Our comprehensive approach includes SE examination, plant concept development, layout design, equipment specification, system integration, and full documentation.
Manufacturing Applications
Expert solutions across all BIW joining and assembly technologies
Spot Welding
Resistance spot welding systems for high-strength joints
Arc Welding
MIG/MAG welding for structural components
Laser Welding
Precision laser systems for critical joints
Stud/Nut Welding
Automated fastener welding solutions
Roller Hemming
Robotic hemming for closure panels
Adhesive Bonding
Automated glue dispensing systems
Material Handling
Robotic and automated part transfer
Clinching
Mechanical joining without heat
Measuring
In-line dimensional verification
Press Automation
Stamping line integration
Machine Tending
Robotic loading and unloading
Curing
Adhesive curing systems
Auxiliary Paint Shop Tooling
Specialized solutions ensuring movable attachments are held in defined positions throughout the painting process.
Positioning Tools
- Door opening angle tools
- Tailgate positioning fixtures
- Hood alignment systems
- Sliding door fixtures
- B-pillar dummies
- Hinge-free transport solutions
Transport Systems
- Front load carriers
- Rear load carriers
- Overhead conveyor systems
- Immersion bath carriers
- Paint line transport pallets
- Body shell handling fixtures
Repair & Maintenance Tools
- Bumper paint frame fixtures
- Repair holding fixtures
- Polishing support tools
- Rework stations
- Touch-up fixtures
- Quality inspection stands
Paint Process Integration
Our paint shop tooling solutions ensure consistent part positioning throughout the entire painting process, from e-coat immersion through topcoat application. Each tool is designed to withstand harsh chemical environments while maintaining precise dimensional control.
Hang-On Parts Assembly Solutions
Comprehensive fixtures and assembly devices for all exterior closure systems, developed in close cooperation with customers.
Door Assembly Systems
Complete mounting and assembly solutions for front, rear, and sliding door systems to body-in-white.
- Front door mounting fixtures
- Rear door assembly tools
- Sliding door mechanisms
- Cargo door systems
- Door hinge fixtures
- Alignment and adjustment tools
Closure Panel Fixtures
Precision mounting equipment for hoods, decklids, liftgates, and other closure components.
- Hood mounting fixtures
- Decklid assembly tools
- Liftgate installation systems
- Tailgate mounting devices
- Gap and flush control tools
- Weatherstrip installation aids
Fender & Exterior Parts
Specialized fixtures for mounting fenders and other exterior add-on components to the body structure.
- Fender mounting fixtures
- Bumper assembly tools
- Rocker panel fixtures
- Exterior trim mounting aids
- Lamp assembly fixtures
- Grille installation tools
Assembly Process Excellence
Our hang-on parts solutions are developed through comprehensive assembly studies that examine technical feasibility, establish optimal clamping schemes, determine automation levels, and create detailed line layouts. This ensures minimum tolerances and maximum quality in the final assembly.
Aerospace Tooling Solutions
Precision tooling for aerospace applications, meeting the exacting standards of the aviation industry.
Composite Manufacturing Tooling
- Lay-up molds for ply sets
- Ply and core locating templates
- Trim and drill jigs
- Profile tools
- Bonding profile tools
- Joggle dies
Assembly & Machining Fixtures
- Final assembly jigs
- Secondary assembly jigs
- Mill fixtures
- Secondary mill fixtures
- Bonding assembly jigs
- Hand welding fixtures
Specialized Tooling
- Drill jigs and templates
- Hydro-form dies
- Stretch form tools
- Extraction and rotation tools
- Transport jigs
- Test fixture assemblies
FEA & Structural Analysis
Comprehensive structural analysis using HyperWorks and Optistruct for stress analysis, fatigue evaluation, and design optimization. All aerospace tooling is validated for structural integrity and durability.
Quality Measurement & Checking Fixtures
30+ years of expertise in precision measurement systems and quality validation tooling for automotive body shops.
Individual Part Gauges
- Stamping gauges for sheet metal parts
- Visual control equipment
- Dimensional measurement systems
- Part acceptance/rejection criteria
- Quick inspection tools
Assembly Gauges
- Ring gauges for doors and closures
- Opening plug gauges
- Assembly verification fixtures
- Dry-build checking equipment
- Visual control systems
Precision Coordination Fixtures
- PCF (Part Coordination Fixtures)
- Exterior part coordination fixtures
- Interior cubing bucks
- Exterior cubing bucks
- Holding fixtures for CMM
- SPC (Statistical Process Control) tooling
30+ Years Experience
Proven expertise in precision measurement tooling across diverse automotive applications
OEM Standards Compliance
All gauges designed to meet stringent OEM quality requirements and validation protocols
Modular Design
Flexible gauge configurations adaptable to changing production requirements
In-Line Integration
Seamless integration with production lines for real-time quality monitoring
Why Choose Advance Mechanical Services
Comprehensive value proposition for automotive OEMs and manufacturers worldwide
End-to-End Expertise
From conceptual design through production commissioning, we handle every aspect of your BIW solution implementation
Advanced Technology
Access to industry-leading software tools, simulation platforms, and manufacturing technologies
Global Experience
25+ global OEM clients and 500+ completed projects across diverse market segments and regions
Expert Team
200+ design engineers with specialized expertise in BIW engineering, simulation, and controls
Quality Assurance
Comprehensive quality protocols ensuring compliance with OEM standards and international regulations
Innovation Focus
Continuous investment in emerging technologies, automation solutions, and manufacturing excellence
System Integration & Support Services
Comprehensive services ensuring seamless implementation and optimal performance of your BIW systems
Robotic Systems Integration
Complete integration of robotic solutions with your production line infrastructure.
- ABB Authorized Value Provider (AVP)
- Multi-brand robot coordination
- End effector integration
- Safety system compliance
- Collaborative robotics implementation
- Performance optimization
Controls & Automation Systems
Full electrical and controls engineering for modern automated manufacturing lines.
- PLC architecture and programming
- HMI development and deployment
- Safety control systems
- Virtual commissioning
- SCADA integration
- Industry 4.0 connectivity
Installation & Commissioning
Expert on-site support ensuring successful system deployment and production ramp-up.
- Installation supervision
- System testing and validation
- Production tryout support
- Operator training programs
- Maintenance team upskilling
- Post-launch optimization
Proven Track Record
Delivering measurable results across global automotive manufacturing
500+
Projects Successfully Delivered
29+
Years of Industry Excellence
25+
Global OEM Partnerships
200+
Specialized Engineers
Transform Your BIW Manufacturing Today
Discover how our comprehensive solutions can optimize your production efficiency and quality
