In just over 20 years, EPALFER has grown into one of Europe’s leading independent toolmakers for the automotive industry. Located in Segadães, Portugal, EPALFER employs nearly 100 people and provides design, production, and try-out services for prototypes and small series, as well as progressive and transfer tools.
For founder and CEO Eduardo Oliveira and his partner Paulo Almeida, the journey has been one of bold risk-taking and innovative approaches, which ultimately paid off. Here, Oliveira shares his story of perseverance, vision, and the relentless pursuit of excellence that transformed EPALFER from a small local business into a key player in the global automotive tooling sector.
Fig. 1: Eduardo Oliveira (left) & Paulo Almeida
Small Start, Big Ambition
When Paulo and I founded EPALFER back in 2002, our vision was simple: to create a stamping company that could tackle the most complex sheet metal parts with precision and efficiency. But as the years have passed, we’ve evolved into something much more—a company built on innovation, advanced technology, and strong customer partnerships.
Paulo and I had been working in the toolmaking industry for some time. We knew it inside and out and saw an opportunity to carve out something of our own. But make no mistake—it was a risky venture. We started with just two employees: I handled design, and Paulo managed production.
We began modestly, building tools for the locking industry. This was our bread and butter in the early days, giving us a solid foundation in toolmaking. However, it wasn’t long before we realized that if we wanted to grow, we would need to pivot. The automotive industry was a much bigger market, with more complex and challenging demands. Moving into this sector required significant investments in technology and skills, but we were ready to take that leap.
Fig. 2: Eduardo & Paulo at the workshop
Beating the Big Players by Breaking the Mold
When we first entered the market, we were up against formidable competition. The European toolmaking industry is full of established players with strong reputations and long-standing relationships with major clients. Breaking into that market was no small feat.
But here’s the thing: many of those companies were still using older, outdated technologies. They were efficient at producing standard parts, but when it came to complex, high-precision components, they struggled.
We saw this as our opportunity. We recognized early on that the automotive industry was evolving, with an increasing demand for more complex and lightweight parts. These weren’t the kind of components you could produce with traditional methods. We made it our mission to focus on complex projects that others couldn’t or wouldn’t take on. We invested in the latest technology, honed our skills, and positioned ourselves as the go-to company for difficult projects. And it worked.
Fig. 3: 3D laser cut machine
Fig. 4: View of a complete progressive die
Breakthroughs and Battlegrounds
One pivotal moment came in 2005 when we produced our first progressive tool for a Tier 1 automotive supplier. This was our big break. Building that first progressive tool wasn’t just about showcasing our technical abilities; it was about establishing trust. The automotive industry is demanding, and the stakes are high—when you’re working with Tier 1 suppliers, there’s no room for error. Delivering that tool on time and with the required level of precision opened doors for us and put us on the map.
That said, we faced challenges—some I could never have imagined. One of the biggest was the economic downturn, which hit the automotive industry hard. I remember sitting in the office with Paulo, trying to figure out how to keep the business afloat. There were sleepless nights and tough decisions. We had to streamline our operations and find ways to do more with less. It was a tough lesson in flexibility, but one that made us stronger in the long run. Those times taught us the importance of staying nimble, innovating constantly, and never taking success for granted.
Fig. 5: Mounting process for a progressive die
Simulation Software as a Success Driver
Our early investments in technology were a definite growth catalyst. I remember deciding to invest in AutoForm software—a state-of-the-art simulation tool that gave us a massive edge over our competitors. At the time, it was a risky move for a small company like ours. The investment was significant, but it allowed us to optimize tool design and streamline production in ways that were previously impossible. Suddenly, we could improve product quality, shorten development cycles, and reduce costs, enabling us to offer more competitive pricing.
One key benefit of simulation is that it empowers us to have more meaningful discussions with our customers. When they ask specific technical questions—like “How will the material behave under these stress conditions?” or “Can we optimize the blank holder force?”—we can provide concrete answers backed by simulation data. This level of detail improves the buy-off process and strengthens our relationships with clients.
Fig. 6: Transport of a die set in the workshop
It’s All About Teamwork
But the simulation is just one part of the story. At the heart of EPALFER’s success is the expertise of our engineering and try-out teams. Today, we employ 95 people, and every single one of them contributes to what makes this company work. When we transition from digital simulations to physical try-outs, our team ensures that the process is as seamless as possible. Every tool is tested, adjusted, and fine-tuned with meticulous attention to detail, ensuring the final product meets or exceeds customer expectations.
From day one, we’ve focused on providing opportunities for continuous learning and growth. I’m proud to say that we’ve built a positive work environment where people are encouraged to innovate and push boundaries. Attracting and retaining talent in this industry isn’t easy, especially when competing with bigger, more established companies. But by investing in our employees, we’ve managed to build a strong team that drives our success.
Fig. 7: Parts produced and transported to storage
Connecting with Customers’ Needs
What really sets EPALFER apart is our commitment to understanding our customers’ needs. When working in the automotive sector, particularly on Body-in-White, seating, battery, and suspension systems, the requirements are incredibly specific and demanding. We don’t just produce tools; we provide holistic, production lifecycle solutions tailored to meet the precise needs of our clients—from simulation and 2D/3D laser cutting to development and production.
Being customer-centric is vital to our approach. When clients know you’re invested in their success and delivering high-quality tools that exceed expectations, they keep coming back. We value being a trusted partner, not just a supplier, and seek to build long-term, collaborative relationships.
Fig. 8: U-shape parts
Risk Taking to Win
Above all, at EPALFER, we’ve never been afraid to take risks. We took a risk by shifting from the locking industry to the automotive sector. We took a risk by investing in cutting-edge technology while still a small company. And we took a risk every time we bid on a project that pushed the limits. But those risks have paid off, and today, we’re stronger for it.
Looking back now, it’s clear that our ability to innovate and stay ahead of the curve has been crucial. In this industry, you can’t afford to be complacent. The automotive world is always changing—new materials, new technologies, and new demands. For instance, the shift towards electric vehicles presents new opportunities, particularly in battery and structural components. We’re ready for that challenge, just as we’ve been ready for every challenge that’s come our way.
As we move forward, I am optimistic about the future. Our goal is to continue investing in cutting-edge technology, adopt sustainable practices, and leverage AI and machine learning to deliver the best possible solutions to our clients. We’ll keep investing in our people, new technologies, and the things that matter most to us: quality, reliability, and customer satisfaction.
