The physicist Bernhard Schaeffer founds the family business – and tinkers with one of his first successes: the self-developed dynamometer, an amusement machine that causes a stir all over Europe. In the 1960s and 1970s, around 10,000 units are produced in-house, manufactured and sold by hand – true Berlin engineering.

At the end of the 1970s, Bernhard Schaeffer launches a new generation of his machines: the Power Rocket. The robust device with cult status becomes a fixture at many of Berlin’s fairgrounds – and remains in use there until the 1990s.

A new era begins in the 1980s. The company shifts its focus to the development and production of measuring equipment for fundamental thermodynamic research. Instead of consumer electronics, it now produces precise instruments for scientific applications.

A new chapter began with Jörg and Kai Schaeffer, the sons of the company’s founder. One was a computer engineer, the other a physicist – together they bring electronics and software expertise to the company and established a limited partnership. Although front panels for measuring systems continued to be crafted by hand, the digital future was already knocking at the door.

Files and drill presses had had their day: the first CNC milling machine was introduced in the production process. This new technology enabled front panels to be manufactured with greater precision and repeatability than ever before. Yet the process remained complex – each machine still needed to be programmed manually and operated individually. Between design, data preparation and actual production, there were still many intermediate steps that demanded both time and expertise.

Programming each CNC machine job still required considerable effort. To streamline the process from design to production, Kai Schaeffer developed a dedicated CAD/CAM system specifically for front panels – the Front Panel Designer. This system formed the technical foundation for customised manufacturing, making it possible to manufacture front panels cost-effectively, even from a single unit.

The Front Panel Designer went online. Customers could now design, calculate and order their own products. The response was overwhelming – demand for customised front panels grew rapidly. The company was now fully focused on producing bespoke, customer-specific parts.

The growing order volume soon meant that the company’s private workshop in Berlin-Zehlendorf was now too small. In early 2001, the company relocated to larger premises on Hohentwielsteig, equipped with four CNC machines and a team of five. The new site offered around 450 m² of production space. Founder Bernhard Schaeffer remained actively involved but increasingly focused on his own research projects.

Success sets a precedent – and crosses borders: The partner company Front Panel Express, LLC was established in Seattle (USA) and has continued to grow steadily to this day. The software, production and philosophy remained the same – only the time zone changed.

Schaeffer Apparatebau KG was transformed into Schaeffer AG – a step that strengthened the company’s structure and positioned it for continued growth. With the new legal form, Jörg and Kai Schaeffer officially assumed executive management. At the same time, an additional 500 m² of production space created capacity for increasing order volumes and more streamlined processes.

The move to Berlin-Marienfelde marked an important milestone. With around 2,500 m² of production space and a team of 50, Schaeffer AG expanded its manufacturing capabilities. At the same time, internal processes were systematically automated and digitally networked to handle growing demand more efficiently and reliably.

In manufacturing practice, a common issue arose: standard press-fit threaded studs left visible marks on thin front panels and damaged the anodised surface. To address this, Schaeffer AG developed its own process, using adhesive threaded studs – an in-house innovation that enhanced both visual quality and durability.

After years of intensive testing, UV digital printing was now established as a standard production option. This technology enabled front panels to be designed in full colour and with exceptional detail – from graphic elements and photographs to complex designs. With Version 5.0, the import of print data was now directly integrated into the Front Panel Designer.

Schaeffer AG celebrates 20 years of front panel history. With the new webshop, customers can now manage their orders online. Front Panel Designer gains a 3D preview and STEP export – features that further simplify the design process and improve data integration into CAD systems.

Today, Schaeffer AG operates in Berlin with a team of over 60 professionals and 12 CNC machines, supported by around 20 colleagues at Front Panel Express in Seattle. Despite continued growth and automation, the core remains unchanged: precision, quality and a passion for innovation – delivering custom front panels, enclosures, milled parts and nameplates, starting from a single unit.

The new DXF import function makes it significantly easier to transfer outer contours, drill holes and cut-outs, noticeably shortening the path to a finished front panel. With the integration of the scale generator, the Front Panel Designer fulfils a frequently expressed customer request and enables precise creation of scales directly within the software.

The Front Panel Designer now has a web-based twin: the same software is now available directly in a browser – no installation required and with the same familiar workflow. The web version already covers many key functions and provides quick access to existing designs, regardless of the computer being used.

Schaeffer AG continues its growth trajectory, opening a new site in Ningbo, China, at the beginning of 2026. With locations in Berlin, Seattle and now Ningbo, the company is building a global network that enables faster and more direct service for customers in every region.

Der Frontplatten Designer wird um einen KI-Assistenten erweitert. Über Texteingaben lassen sich Elemente wie Bohrungen, Ausschnitte und Beschriftungen automatisch erstellen und anschließend weiterbearbeiten.