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Scheurer Swiss receives order to develop carbon reinforced thread inserts for sensors monitoring natural hazards.

With over thirty years of experience in lightweight construction for Formula 1, Scheurer Swiss GmbH is considered a specialist in the field of fibre composite technology. Proven in delivering top performance, it uses state-of-the-art technologies such as carbon reinforced 3D printing for customized solutions. Swiss sensor and digitalization professional, Aartesys AG, has commissioned the lightweight expert to design and manufacture custom carbon reinforced thread inserts for its revolutionary geo-sensor system, AarteLink®. It is used for monitoring and alerting in the event of natural hazards.

Aartelink®, the Swiss Army Knife in Natural Hazard Prevention

Natural disasters such as rockfalls, avalanches, landslides and floods are a major threat to the population in Switzerland as well. Roads, railroad lines and entire villages, for example, must be protected against avalanches and rockfalls, and natural hazard officers and blue-light organizations must be notified in good time in the event of changes and imminent dangers. With AarteLink®, the Biel-based company Aartesys has created a groundbreaking system for the prevention of natural disasters. The low-maintenance and robust geo-alarm system is a combination of sensor technology, sophisticated electronics and telecommunications technology. It reliably monitors and alerts to natural hazards, uncompromisingly designed for tough everyday use in the field.

Carbon reinforced thread inserts from Scheurer Swiss are part of the AarteLink® geo early warning system, which climbers install to detect natural hazards on steep rock slopes.

Carbon reinforced thread inserts from Scheurer Swiss are part of the AarteLink® geo early warning system, which climbers install to detect natural hazards on steep rock slopes.

When natural hazard events occur, action must be taken quickly. It is therefore of the utmost importance that the geo-sensor system immediately detects and accurately measures vibrations and movements in all directions, independent of vegetation and weather conditions, in the sense of an early warning system. On the other hand, installation and commissioning must be as simple as possible, even in hard-to-reach places such as rock crevices, and must function flawlessly so that the geo-sensor is ready for use in the shortest possible time. Small, lightweight and easily transportable, yet stable and highly precise components are therefore central. Carbon the solution.

Carbon at dizzying heights detects geohazards

For Aartesys’ latest protection project on Monte San Salvatore in Switzerland’s sunny canton Ticino, the leading company in the field of sensory monitoring of natural hazards has called in two more experts.

At Lake Lugano on Monte San Salvatore in Ticino, carbon reinforced thread inserts from Scheurer Swiss are installed in carbon pipes that detect natural hazards at an early stage.

At Lake Lugano on Monte San Salvatore in Ticino, carbon reinforced thread inserts from Scheurer Swiss are installed in carbon pipes that detect natural hazards at an early stage.

In addition to the fibre composite and 3D printing specialist, Scheurer Swiss GmbH, a company specializing in the production of round profiles made of carbon and fibreglass has also been engaged. The latter supplies the carbon tubes for crack monitoring, which immediately record and precisely measure vibrations as well as changes at critical rock crevices.

Scheurer Swiss develops carbon reinforced thread inserts for Geo Alarm System Aartelink®.

Scheurer Swiss develops carbon reinforced thread inserts for Geo Alarm System Aartelink®.

Scheurer Swiss is responsible for the carbon reinforced thread inserts with glass fibre insulation and a sophisticated injection bonding system based on fast curing epoxy, with which the thread inserts can be fixed in the carbon tubes on both sides within a few minutes and mounted on the rock at a height of several hundred meters.

The starting point for both the material selection of the carbon measuring tubes and the development of the carbon reinforced thread inserts and the unique bonding mechanism was the individual requirement of the customer Aartesys for a lightweight solution with low material input, fast and flexible to use, so that the climbers can install the geo alarm system AarteLink® in the shortest possible time even on steep rock slopes. Based on specially designed 3D computer data, one of the most advanced lightweight technologies, additive manufacturing, was used to produce the threaded inserts. “Carbon reinforced 3D printing meets all the criteria of producing one-of-a-kind items like these custom threaded inserts, which need to be lightweight yet strong, and as cost-effective as possible to produce when needed. “, says fibre composite and lightweight construction expert at Scheurer Swiss GmbH, Dominik Scheurer.

Ultra-stable bonding mechanism defies the forces of nature

For the present Aartesys project on Monte San Salvatore in Ticino, the carbon tubes supplied are cut to the required length at Scheurer Swiss and fitted with the carbon reinforced thread inserts before being installed in the rock faces as an AarteLink® early warning system.

Scheurer Swiss designs individual hand tools that enable the fitters to cut carbon tubes to length even at dizzy heights.

Scheurer Swiss designs individual hand tools that enable the fitters to cut carbon tubes to length even at dizzy heights.

If required, the carbon measuring tubes can also be cut to length and bonded directly on site. For this purpose, Scheurer Swiss has designed a customized hand tool – it serves as a sageblade guide for the handsage for capping the carbon tubes – and prepared a manual for professional cutting and gluing. Scheurer, engineer and owner of Scheurer Swiss GmbH, points out, “With the help of the specially developed and extremely fast-curing injection adhesive, the fitters succeed in gluing the carbon reinforced threaded inserts into the carbon tubes, which were previously cut to length by hand, even at dizzying heights.”

Natural hazard events are always a race against time. Timely alerting can save lives. AarteLink® must therefore perfectly meet all the criteria of an early warning system for monitoring natural hazards of all kinds. For this reason, Aartesys subjected the stability of the carbon reinforced thread inserts and the resistance of the unique bonding mechanism of Scheurer Swiss GmbH to a rigorous mechanical stress test in advance. Martin von Känel, CEO of Aartesys AG, is very satisfied: “The thread inserts with the epoxy bonding system of Scheurer Swiss prove their high reliability and easily withstand a tensile test of up to 400 kilograms. “, and praises Scheurer Swiss: “The positive result of our load test clearly shows the expert choice of materials and testifies to successful Swiss engineering.”

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Scheurer Swiss uses 3D printing to produce blue light dummies for the conversion of a former Swiss fire engine into a true-to-the-original event vehicle. 

Scheurer Swiss GmbH, a specialist in the field of product development with state-of-the-art fibre composite and lightweight construction technologies, was recently commissioned with the additive manufacturing of three blue light dummies for the conversion of a fire engine once used as a company fire brigade vehicle produced by the well-known Swiss motor vehicle manufacturer “General Dynamics European Land Systems – Mowag GmbH” into an original vintage event bus. The blue light fairings, made of highly UV light and weather resistant plastic, serve as a replacement for the originally functional blue lights of the original Swiss fire engine built in 1987, as their operation, within the framework of the civil use of the vehicle, is not permitted.

From fire engine to vintage car thanks to additive manufacturing 

In the modern lightweight construction technology also known as 3D printing, a digital model is transformed into a physical, three-dimensional component by adding material layer by layer. A special feature of additive manufacturing is that the objects are produced without tools and without complex moulds, directly on the basis of 3D computer data, so-called rapid product development. Compared to conventional manufacturing processes, this increases flexibility – in particular, components with a high degree of customisation can be produced promptly and cost-efficiently with the necessary stability and functionality.

Scheurer Swiss uses 3D printing to produce dummy blue lights for the conversion of an old fire truck into an event bus.

3D printing allows the flexible and fast production of stable, resistant and cost-efficient components and one-offs based on a computer model.

“We deliberately chose 3D printing for the production of the fire brigade blue light dummies. It allows us to produce a wide variety of stable and resistant components and unique items like these, based on a computer model, flexibly, quickly and with the lowest possible material consumption in a cost-efficient manner. “, says lightweight construction expert and owner of Scheurer Swiss, Dominik Scheurer, and continues: “Sometimes, as in this case, even a simple hand sketch from the customer is sufficient as input for the subsequent computer-aided 3D design of the customised components. ”

Plastics as a material for 3D printing 

On one and the same 3D printer, different additive manufacturing processes can be used to process different materials, for example nylon or carbon reinforced plastics. In the case of the blue light cladding of the original Mowag fire truck, which was to be converted into an event bus, Scheurer opted for the highly weather-resistant ASA plastic. The engineer emphasises: “Due to its high UV and weather resistance, this plastic is ideally suited for end products that are used outdoors. ”

Scheurer Swiss uses 3D printing to produce dummy blue lights for the conversion of an old fire truck into an event bus.

The 3D-printed blue light dummies, made from UV- and weather-resistant ASA plastic, were further processed using the classic painting process.

3D-printed components made of these and other, also fibre-reinforced materials, can also be excellently processed. For example, the new blue lights of the Mowag B300 were further processed after printing at a body shop using the classic painting process. First the covers were filled, then painted with water-based paint. The filler smoothes out any unevenness and also serves as corrosion protection. It also provides optimal adhesion for the subsequent paint coat. “In this case, our customer opted for a paint finish in ultramarine blue to come as close as possible to the original blue lights,” Scheurer shares.

3D printing: the future of production technology 

The lightweight construction expert is certain: “Additive manufacturing is currently one of the most modern lightweight construction technologies and is shaping the future of the manufacturing industry like hardly any other process. The intention is clear: even more flexibility, creativity and cost efficiency in product development. ”

Thanks to its roots in Formula 1 motorsport, Scheurer Swiss has over thirty years of experience in the field of lightweight construction and is the only provider in Switzerland to offer a complete service: from consulting, design and engineering to production – all from a single source. We are happy to advise you!

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Scheurer Swiss supports the focus project “Rowesys” – Robotic Weeding System – of ETH Zurich with its engineering know-how and supplies 3D-printed carbon-reinforced robot components.

The engineering company Scheurer Swiss GmbH, known for its many years of expertise with fibre composite technologies, is supporting the “Rowesys” – Robotic Weeding System – project of ETH Zurich as a gold sponsor with its engineering expertise and is printing carbon-reinforced 3D components for the agricultural robot on behalf of the team. With this concept, ten motivated ETH students are pursuing the goal of developing a sustainable alternative for the use of herbicides in agriculture. Their autonomous agricultural robot for weed removal has just gone into practical testing.

Carbon-reinforced material revolutionizes agriculture

“Rosie”, the unprecedented autonomous agricultural robot, was developed by ETH students in collaboration with Scheurer Swiss as a gold sponsor and is expected to replace pesticides in the future.

The ETH Zurich focus project “Rowesys”, supported by Scheurer Swiss, impressively demonstrates how damage to people and the environment can be minimised with the help of digitalisation and smart technology. With this goal in mind, ten motivated ETH students, supported by eight expert coaches and sponsors, have been working on the development of the “Rowesys” agricultural robot since last September.
The underlying concept is based on mechanical weed killing. The result is a functional prototype for sugar beet fields, because these require a relatively high use of herbicides. “Rowesys” already meets the requirements of an autonomous agricultural robot in terms of efficiency, reliability, autonomy, safety and user-friendliness to a large extent. Not least thanks to the use of cost-efficient carbon-reinforced material from the 3D printer, which, in addition to the monetary benefits, also offers practically unlimited design possibilities.

For example, the agricultural robot has been equipped with wafer-thin carbon-reinforced plastic slats that are backed by LEDs to indicate the robot status at all times.

Scheurer Swiss supports the focus project "Rowesys" - Robotic Weeding System - of ETH Zurich

Wafer-thin carbon-reinforced plastic slats from the 3D printer of Scheurer Swiss GmbH.

Another filigree component in turn serves as an interface between the aluminium chassis and the robot’s electronics. The unusual shape of the connector is designed in such a way that not a single gram of superfluous material is used, so as not to weigh down the robot unnecessarily. At the same time, the component must be ultra-stable to hold the connection.

Scheurer Swiss supports the focus project "Rowesys" - Robotic Weeding System - of ETH Zurich

Carbon-reinforced connecting piece between the case and electronics, printed in 3D by Scheurer Swiss.

“Only with the technology of carbon-reinforced 3D printing is it even possible to produce such a precisely fitting, filigree and yet stable component.

The carbon reinforced 3D printing technology recommended by Scheurer Swiss is the perfect solution in terms of lightweight construction, design flexibility and stability as well as manufacturing time and production costs.

We supported the Rowesys team with our know-how in the field of fibre composite technologies in an advisory capacity and operationally incorporated our many years of expertise from the development of highly efficient composite components for motor sports into the development and 3D printing of the carbon-reinforced components for the agricultural robot,” explains Dominik Scheurer, CEO of Scheurer Swiss GmbH.

The agricultural robot is to replace pesticides

The agricultural robot pulls small ploughs through the soil, which destroy the weeds between the rows of plants by pulling the roots to the surface from the ground where the weeds dry up. The robot drives autonomously through the rows, detects the end of the field with the help of the built-in cameras and switches to the next untilled row. This process is repeated until the end of the field is reached.

The “Rowesys” project at ETH Zurich, which is supported by Scheurer Swiss, impressively demonstrates how damage to people and the environment can be minimized with the help of digitalization and smart technology.

The practical test has shown that with “Rowesys” both the use of herbicides and the pollution of groundwater, air and produced goods can be massively reduced. “What motivated me about this project, apart from the relevance of what I learned and the chance to gain practical experience in teamwork, was the sustainability of herbicide-free sugar beet cultivation. Because up to now, there has been no investment in more sustainable production in this area of agriculture,” says Nico Burger, Software & Controls Team Rowesys.
“The focus project “Rowesys” is an example of how digitisation and the use of innovative materials can produce efficient and intelligent technical achievements. We congratulate the Rowesys team on their success and are pleased that we were able to support the team with our expertise in an advisory and operational capacity right up to the practical test”, Scheurer announced.

Your project in good hands

Scheurer Swiss GmbH is the only provider in Switzerland that offers the complete process from consulting to engineering and production within its service portfolio in the field of lightweight composite engineering. In addition, Scheurer Swiss GmbH provides high performance composite know-how in the context of professional and licensed personnel placement as well as customer-specific composite training on a long-term basis. We will be happy to advise you!

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Scheurer Swiss GmbH is commissioned to manufacture carbon-reinforced 3D printing components for the latest generation of the racing series “Castrol Toyota Racing Series“.

The well-known racing series “Castrol Toyota Racing Series” (TRS) based on a Formula 3 chassis is entering the next round: “Toyota GAZOO Racing New Zealand” has presented a brand new, more powerful racing car for the TRS 2020, the “Toyota FT-60”.
Scheurer Swiss GmbH supplied Toyota Gazoo Racing New Zealand with high-quality carbon-reinforced 3D printing components for the latest generation of the Toyota FT engine on behalf of the two renowned New Zealand-based companies “David Gouk Race Engines” and “Häberlin Composites”.

Scheurer Swiss GmbH is contracted to manufacture carbon reinforced 3D printed components for the latest generation of the racing series "Castrol Toyota Racing Series".

Scheurer Swiss GmbH is contracted to manufacture carbon reinforced 3D printed components for the latest generation of the racing series “Castrol Toyota Racing Series”.

The third generation race car of the Castrol Toyota Racing Series is based on a regional Formula 3-specific Tatuus chassis, powered by a two-litre Turbo 8AR FTS engine – a racing version of the 8AR FTS engine used in both Toyota and Lexus road vehicles. The engine is capable of producing 285 hp, a sharp increase over the 215 hp produced by the previous 1.8-liter unit.

Successful test run for 3D printing engine parts from Scheurer Swiss

The new racing car first hit the track in Italy in July, even before its race debut in 2020. Formula 2 and European Le Mans Series driver, Arjun Maini, completed 900 kilometres in the Toyota FT-60, spread over three different tracks – Vairano, Cremona and Franciacorta.

Formula 2 and European Le Mans Series driver, Arjun Maini, tests the new Toyota FT-60 and is satisfied.

Formula 2 and European Le Mans Series driver, Arjun Maini, tests the new Toyota FT-60 and is satisfied.

“It was a very positive first test,” said Maini, who finished fourth in the 2015 TRS season with the previous FT-50 race car. “The new engine ran very smoothly, it is powerful and the handling very good. Gear changes and downshifts also feel very good in combination with the new engine”.

Scheurer Swiss GmbH was commissioned by Häberlin Composites to optimise the design of carbon reinforced engine components for the test series of the Toyota FT-60 and to produce them in a very short time.

Scheurer Swiss GmbH was commissioned by Häberlin Composites to optimise the design of carbon reinforced engine components for the test series of the Toyota FT-60 and to produce them in a very short time.

“Scheurer Swiss GmbH has optimised the design of the carbon-reinforced engine components for the test series of the Toyota FT-60 on our behalf and produced them in the shortest possible time,” says Gregor Häberlin, owner of Häberlin Composites, with satisfaction. Häberlin Composites itself also supplies carbon parts for the Toyota FT-60, manufactured using the lamination process.

Carbon reinforced 3D printing makes it possible to use customised components outside of racing.

Carbon reinforced 3D printing makes it possible to use customised components outside of racing.

“It was possible only thanks to 3D printing to deliver the tailor-made Toyota FT-60 components of the test series in such a short time,” says Dominik Scheurer, CEO of Scheurer Swiss.
He confirms that the carbon-reinforced 3D printing process can also be used for industrial applications in the automotive sector, especially after the successful race track test run.

Planned series production of Scheurer Swiss engine parts

According to David Gouk of David Gouk Race Engines, the texture and material in the tests were not only visually convincing, but also withstood the enormous speed and heat as well as the compressive forces on the race track. “We are planning to go into series production soon with the 3D-printed carbon-reinforced engine components from Scheurer Swiss,” says the owner, who is considered a luminary in the field of engine development and has been successfully developing the engines of the Castrol Toyota Racing Series for years.

According to David Gouk of David Gouk Race Engines, the texture and material not only impressed visually in the tests, but also withstood the enormous speed and heat as well as the pressure forces on the race track.

According to David Gouk of David Gouk Race Engines, the texture and material not only impressed visually in the tests, but also withstood the enormous speed and heat as well as the pressure forces on the race track.

Toyota Racing series manager, Nicolas Caillol, is very satisfied with the quality of the 3D printed engine parts for the Toyota FT-60 supplied by Scheurer Swiss.

Toyota Racing series manager, Nicolas Caillol, is very satisfied with the quality of the 3D printed engine parts for the Toyota FT-60 supplied by Scheurer Swiss.

“We are very satisfied with the advice and service provided by Scheurer Swiss, in particular the flawless and fast delivery of the urgently needed carbon-reinforced components for the Toyota FT-60 test series”, Gouk continues.

Toyota Racing Series Manager, Nicolas Caillol, says: “The FT-60 is a modern car that offers more power and more drive than anything we have had in production before. We are very pleased with the quality of the 3D-printed engine parts that Scheurer Swiss supplied to us”.

Toyota Racing Series as a springboard for Formula 1 careers

The 2020 season of the Castrol Toyota Racing Series starts at the Highlands Motorsport Park in New Zealand in January 2020 and ends, after five consecutive weekends, with the New Zealand Grand Prix at the Manfeild Circuit “Chris Amon” in mid-February – one of the only two events outside Formula 1 that is officially allowed to use the term “Grand Prix”. Like this year, the series winner will receive up to seven super license points for possible Formula 1 careers.

“It’s a globally relevant car and a globally relevant championship for any serious young racer, and we hope to attract even more aspiring stars who want to take a step up in their careers. They can come from Formula 4, Formula 3, the women’s W Series or other Tier 3 categories of FIA leaders. It’s even relevant for those who have been successful in the Tier 2 categories, who want to consolidate and improve their skills or earn more super license points as they take their final step towards F1,” affirms Toyota Racing Series Manager Nicolas Caillol.

The Toyota FT-60 is a globally relevant car and the Toyota Racing Series is a globally relevant championship for any serious young racer.

The Toyota FT-60 is a globally relevant car and the Toyota Racing Series is a globally relevant championship for any serious young racer.

The winner of the W Series, Marta Garcia, is also considering the possibility of driving in early 2020 in New Zealand’s Castrol Toyota Racing Series.
The 19-year-old Spaniard dominated the Norisring race of the first season of the all-female Open Wheeler Series and finally finished fourth in the overall standings, with prize money of $100,000 and an automatic invitation to the 2020 W Series competition.

Scheurer Swiss develops and produces composites at the highest level

The owners of Scheurer Swiss GmbH, Dominik Scheurer (CEO) and Robert Tween (CTO), have both been involved in racing and motor sports in composite engineering for many years, including Jordan F1, Sauber F1 and Toyota Motorsport, and with the right design and the right composite materials they provided the necessary properties for the highly efficient mechanical performance of a Formula 1 racing car.

Scheurer Swiss GmbH is known for the development of highly efficient ultra-light and extremely stable composite components made of carbon, glass fibre or other fibre composites. It develops and produces customer-specific composite components that are used in racing and motor sports, aerospace, nautics, defence and security as well as industry. The highly efficient product development with state-of-the-art fibre composite technologies, including 3D printing, is rounded off with professional, state-licensed personnel recruitment and practice-oriented composite training courses – directly at the customer’s site. With over 30 years of experience in Formula 1 engineering, the fibre composite and lightweight construction specialist offers a unique complete service from a single source.

Your project in good hands

Scheurer Swiss GmbH is the perfect partner when it comes to product development with state-of-the-art fibre composite technologies, personnel recruitment and composite training. We will be happy to advise you!

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Thanks to clever engineering, Scheurer Swiss GmbH develops pioneering solution with unique composite carbon 3D print components for a high-tech sailing catamaran.

Exploring turquoise waters in style and peace on board a luxurious high-tech sailing catamaran or crossing oceans on a fast pace – this is what Moonwave Gunboat 60/03 with its hybrid system offers its owner and his guests. The carbon fibre catamaran is taken care off by two competent and friendly crew members who keep it up to date and also at the edge of technology.

Thanks to clever engineering, Scheurer Swiss GmbH develops unique composite 3D printed carbon components for high-tech sailing catamaran.

Thanks to clever engineering, Scheurer Swiss GmbH develops unique composite 3D printed carbon components for high-tech sailing catamaran.

The Moonwave crew recently ordered highly modern and extremely efficient carbon-reinforced 3D-printed composite components from Scheurer Swiss GmbH. It was only thanks to sophisticated engineering and a unique bonding mechanism that it became possible to develop composite carbon 3D print components of the required dimensions. The parts will be fitted in a state-of-the-art titanium rudder bearing system – for this application precision, weight and strength are key factors. With diameters of up to 630 mm, an impressive size for two 3D-printed components, the bearing cages will be an essential feature of making the steering of the luxury catamaran even easier.

Your project in good hands

With the right engineering, the innovative technology of composite carbon 3D print finds the most incredible areas of application – we will be happy to advise you on your journey to an ultra-light, extremely stable future!

You too can benefit from the comprehensive lightweight construction know-how gained from more than 30 years of Formula 1 engineering and our complete service in the field of fibre-reinforced composites, which is unique in Switzerland.

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Composite support for Swiss “Black Star” sailing team

A flying sailboat, a team of seven professional sailors, perfect wind and water conditions – and Scheurer Swiss GmbH with its composite support right in the middle!

As the only service provider in Switzerland, Scheurer Swiss GmbH offers a complete service that, in addition to design and engineering, also includes the production of high-performance and ultra-lightweight fiber composite components as well as the provision of specialist expertise. For example, Scheurer Swiss GmbH supports the first professional German-Swiss GC32 sailing team “Black Star“, which is participating for the first time this year in the internationally known and renowned GC32 Racing Tour, not only from a technical point of view by providing extensive composite support on land and in the water. Scheurer Swiss goes one step further: it also offers active marketing support to the sailing team, which is staffed with international professional sailors and competes for Switzerland, and is personally on site at the races. The Swiss sailing team is happy to take advantage of the all-round service provided by Scheurer Swiss GmbH.

Composite support: Scheurer Swiss supports the first professional swissgerman sailing team "Black Star" at the GC32 Racing Tour.

Composite support: Scheurer Swiss supports the first professional swissgerman sailing team “Black Star” at the GC32 Racing Tour.

At every training session and at each of the five racing events in 2019, Scheurer Swiss GmbH will be sailing alongside in an escort boat, will be up close and personal with the team and, equipped with all the necessary composite emergency materials such as carbon, resin and other adhesives as well as the appropriate tools providing optimum support, either directly on site or back on land. This includes maintenance and servicing work as well as the design, engineering and production of spare parts or accessories, quickly and efficiently using our modern 3D printing technology. At the same time, valuable image and video material is created that the team can use to analyze and improve their training and racing performance, as well as for their website and social media channels – making the “Black Star” sailing team even more attractive to sponsors.
Once again, Scheurer Swiss GmbH is following its corporate philosophy, which is unique in Switzerland: competent 360° complete service from a single source.

We keep our fingers crossed for the new Swiss sailing team – do you?
Fly, Black Star, fly!

Your project in good hands

Would you also like to benefit from our comprehensive lightweight composite know-how from over 30 years of Formula 1 engineering and our complete service, which is unique in Switzerland?

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