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Aluminum fuel tanks for machinery, equipment and vehicle technology

Aluminum fuel tanks are used to store fuels such as gasoline, diesel or even gas. Fuel tanks used in machines, systems and vehicle technology are connected to the combustion chamber and are thus a fundamental component of the fuel supply. In addition to the legal guidelines, aluminum fuel tanks must meet a wide range of requirements.

In daily use, aluminum fuel tanks are constantly exposed to mechanical loads, vibrations and temperature fluctuations. The strength requirements are also further increased by complex geometries for maximum filling volume.

We only produce individual solutions for orders of at least 50 pieces

Aluminum fuel tanks for machinery, equipment and vehicle technology

Customized aluminum fuel tanks from NovaNox®.

With our many years of experience in tank technology, we develop and produce individual aluminum fuel tanks for manufacturers of machines, systems and vehicle technology. From simple to complex geometries, we realize fuel tanks for every installation situation with our modern manufacturing capabilities.

NovaNox® aluminum fuel tanks are therefore always individually adapted to the installation possibilities. In this way, even particularly tight installation spaces are used effectively. At the same time, the filling volume of the fuel tank is utilized to the maximum. This enables a significantly longer fuel supply for machines, systems and vehicles. Ideal conditions for increasing productivity through longer operating times.

Customized aluminum fuel tanks from NovaNox®.

Ready-to-install aluminum fuel tanks from NovaNox®.

Whether tank caps, gauges, sensors or fuel filters - as a system supplier, we deliver aluminum fuel tanks ready for assembly as a system solution. We take over component procurement with full cost transparency, as well as deadline monitoring, quality control and final assembly.

With this process takeover we adjust the fitting accuracy to a high maximum. The high accuracy of fit offers a very high level of convenience during final assembly and reduces assembly times to a minimum. The direct procurement channels also optimize the entire supply chain.

Ready-to-install aluminum fuel tanks from NovaNox®.

Lightweight aluminum fuel tanks from NovaNox®.

Unlike conventional fuel tanks, lightweight NovaNox® fuel tanks are made of high-quality thin aluminum sheet. This special feature offers significant weight savings, especially in automotive and aerospace applications. The weight reductions lower fuel consumption and the resulting operating costs.

Despite the lightweight design, our aluminum fuel tanks made with thin sheet have high strength. This quality feature is ensured by our in-house welding process planning.

Lightweight aluminum fuel tanks from NovaNox®.

Manufacturing process

Manual welding
As a welding company, we have trained personnel and many years of know-how in the field of welding technology. In addition to the automated welding process, we also manufacture hand-welded aluminum fuel tanks. Especially for custom-made products, as well as small and medium-sized series, the manual welding process offers a cost-effective alternative with fast turnaround times. The hand-welded aluminum fuel tanks are manufactured on modern welding tables. Dimensional accuracy is guaranteed by our own fixture construction. In addition, repeatability can be permanently met even with high tolerances.

Automated welding
We carry out the automated welding process using state-of-the-art welding robots. The automated manufacturing process enables very fast and efficient production. This is the ideal prerequisite if high requirements are to be produced cost-effectively while maintaining consistent quality. The automated welding process also offers the highest possible method of welding with extremely high precision. This means that even very complex aluminum fuel tanks with high tolerance requirements can be realized.

Manufacturing process

Corrosion protection and finishes for aluminum fuel tanks

Surface treatments are particularly important in terms of durability, safety and appearance. The durability of aluminum fuel tanks is supported by a permanently corrosion-free, safe and solid surface. At the same time, the aluminum fuel tanks are visually enhanced. With our own powder coating and painting facility, we can realize all RAL colors quickly and in high quality. For optimal corrosion protection, we offer heat-resistant painting, powder coating, as well as pickling and passivation.

Corrosion protection and finishes for aluminum fuel tanks

Custom aluminum fuel tanks


Manufactured manually and automatically

Ready to assemble

Ready to assemble aluminum fuel tanks


To ensure that you are on the safe side during the test phases and also after your customers have put your product into operation, we use FEM calculations to determine the structural strength, fatigue strength and material efficiency of your concept, among other things, in the early development phases. In doing so, we digitally visualize the consequences of different mechanical, thermal and electrical loads by means of linear and non-linear structural-mechanical calculations. The advantage of this is that we can examine the effects of the various influences on the entire product or component for any geometries, even complex ones, before we build prototypes.

The results of these calculations also serve as evidence for technical approvals, product liability and production releases.

NovaNox FEM calculations are performed analytically according to general and international standards. This ensures comparability and reliable results. In detail we do for you

  • linear and non-linear structural mechanics calculations
  • Analysis of deformations, stiffnesses and stability
  • Consideration of natural vibrations
  • Transient structural analysis
  • Collision analyses
  • Temperature field calculation (thermal-stationary or thermal-transient)
  • CAE-supported fatigue analysis with nCode

You will receive technical drawings from us in 2D (in dxf, dwg and pdf formats) and in 3D (in step format). Depending on your needs, we will produce individual part drawings, assembly drawings, general drawings or assembly drawings for you. In addition, you will receive detailed technical documentation for review. This gives you the opportunity to make adjustments or add special requests before production. This means you are on the safe side when the production line starts rolling.

You can be sure that everything will fit perfectly and be implemented without errors. With this range of technical drawings and comprehensive documentation, communication functions precisely throughout your entire development and production process chain. You thus cover the different information needs of each stage and ensure greater efficiency.

In order to achieve a result that is as close to series production as possible, even in the prototype phase, we work closely with you in the development, planning and design of the construction, material and manufacturing process. This ensures optimal results and compliance with your time and cost planning.

For the final touches, we analyze the FAI results and optimize the manufacturing process for maximum efficiency and cost-effectiveness. In doing so, we help to significantly shorten the introduction times and to successfully start series production as planned. This is easy on your project budget and provides optimum security.

From demand planning to logistical handling, we take over the complete process for you. We provide you with a total of 1,200 square meters of storage space as a consignment warehouse to ensure uninterrupted production processes. On the one hand, this saves you costs compared to having your own storage capacity. On the other hand, you can produce more cost-effectively in larger batch sizes.

Your optimum component supply for series production is assured. Your aluminum fuel tanks can be delivered from the consignment warehouse on schedule and flexibly on demand. Your existing logistics processes are fully integrated. The optimal solution for a secure component supply with aluminum fuel tanks from NovaNox® throughout the year.

Quality management

Welding process planning is the basis for selecting the optimal welding process for the specific requirements of your aluminum fuel tanks. Using the right process increases the safety and stability of your aluminum fuel tanks.

Welding process planning also determines and establishes the welding sequence. The optimal sequence of welding operations not only ensures more efficient manufacturing processes for you. It also ensures the longer service life and reliable tightness of your aluminum fuel tanks.

Thanks to type identification, each aluminum fuel tank can be easily traced back to its source. The entire path from manufacture to the last application can be traced in detail over the entire product life. A proof that gives you more security.

Depending on the material and stress of your aluminum fuel tanks, various types of type markings are available:

  • Laser engraving
  • Welded metal plates with laser engraving
  • Self-adhesive metal plates with laser engraving
  • Self-adhesive plastic plates with specific imprint and silicone coating for external protection

Whether symbols, numbers or letters. - You get your personal identification for a constant traceability of your aluminum fuel tanks. The integration solution for optimal, clear route and process reconstruction!

This process from the quality management area gives you the assurance that your aluminum fuel tanks will remain absolutely leak-proof even in continuous operation and under extreme conditions. For your additional security, we are happy to conveniently provide the leak test for each delivery as a written declaration of conformity. You can quickly and easily integrate this NovaNox® test certificate into your overall documentation. We carry out these leak tests for you:

  • Conforming to ECE R34 or 70/21/EEC regulation, we undertake a 100% test with air underwater in our specialized test basin
  • Pressure test
  • Leak test by means of red or fluorescent dyes
  • Ultrasonic testing

Precise documentation of production processes is essential for quality assurance in production. This is because it ensures the high quality of your products.  Complete documentation also holds enormous cost-cutting potential, especially for large projects, because errors and quality deviations can be detected and eliminated at an early stage.

Precisely documented, reproducible processes free up extra time and personnel resources. We offer you this comprehensive documentation for quality management:

  • Initial sample inspection report according to VDA 2, EN 9102
  • Factory certificates 3.1 and 2.2 according to EN 10204
  • Dimensional report by 3D measuring technique (Faro measuring arm)
  • Declaration of conformity for pressure tests

All our documentation can be quickly and easily integrated into your overall documentation.