Real Madrid is one of the world’s most successful football teams – and a visit to the club’s Santiago Bernabéu Stadium is a dream come true for many fans. The spectacular facade of the revamped Bernabéu contains thousands of stainless steel louvres, over half of which were fabricated by Lasercor with millimetre precision using a Trumpf TruLaser 5030 Fiber laser cutter. What made the task particularly challenging was that every louvre is different.

Lasercor’s 16,000 m² production site is home to 23 Trumpf machines, from a TruBend 5130 press brake and TruLaser 5030 Fiber laser cutter to a TruLaser Weld 5000 automated laser welding cell and TruMark Station 7000 laser marking system. The company employs 170 people and generate annual turnover in the region of €30m.

Using Trumpf machines, Lasercor has cut, bent, engraved and welded parts of all shapes and sizes for some 8000 customers. And now that list includes the world-famous Santiago Bernabéu Stadium, where the new roof alone required 8880 metal louvres, with a whole lot more needed for the facade.

The initial specifications stated that all – or at least many – of the louvres would be identical. But during the cutting process, it emerged that each louvre was slightly different, often by a matter of millimetres. And each one had to slot into position perfectly. There were also six different surfaces that were designed to reflect light in different ways.

Lasercor used a TruLaser 5030 Fiber laser cutter with a 12 kW power to precision-cut 4400 louvres, as well as parts for the north and east facades. The company spent 18 months working on the project. However, Lasercor worked so fast it was even able to support some other fabricators involved in the project.

“If one machine isn’t up to the job, then we look for another one; if the material isn’t good enough, we find a better option,” says Lasercor CEO Julián Jiménez Barroso. “None of our machines are more than four years old and we never stop investing.”

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