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Cutting-edge Swiss technology from BERNINA and SFS

BERNINA has stood for Swiss precision since 1893 and has a worldwide reputation for delivering outstanding sewing machines that are both innovative and of high quality. The company is setting standards for advanced sewing technology yet again with its newly launched BERNINA 990. Tegra Medical, a company of the SFS Group, played an important role in the rollout of this exceptional product by developing and manufacturing sophisticated assemblies to ensure that it could be launched quickly, successfully and punctually.

Added value


  • Comprehensive know-how: efficient new parts developed with extremely short turnaround times
  • Customer focus as a strategy: we create tailor-made solutions
  • Long-term partnerships matter: successful together for 30 years

The BERNINA 990, one of BERNINA’s flagship projects, boasts features such as a camera with a scan function, a fully automatic threader and an integrated stitch regulator (BISR) that makes it possible for even inexperienced people to “freehand quilt” precisely with consistent stitch lengths.

BERNINA collaborated with Stamm – now Tegra Medical – to launch the ambitious BERNINA 990 project, which was aimed at integrating the BISR function, i.e. the stitch regulator, into the thread monitoring module. The goal was to enable stitch regulation regardless of the presser foot selected while simultaneously making the best possible use of the very small space available – particularly in something referred to as ruler work applications, which use stencils (rulers) to sew uniform geometric shapes.

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The sensor from SFS

Cutting-edge technology
BERNINA adapted the housing to suit the new function and integrated five plastic lenses – which had already been manufactured by Tegra Medical in the past – to monitor the bobbin thread. Thanks to these tried-and-tested products for the redesigned housing, we had an opportunity to design two more new components in a way that would function well with plastic: a housing cover and a highly complex and sophisticated lens with light and image paths for the sensors. Yet this project hinged not only on precise optics; producing housing components to the highest of standards, both visually and technically, in order to guarantee a perfect fit for the different optical components was also vital.

The new BISR lens called for extremely tight form and positional tolerances of 0.02 mm. The complex geometry meant that there could be no visible seam lines, such as those caused by ejectors or mold releases, that could potentially disrupt signal and light paths.

Our collaboration with Zühlke Engineering Zurich, a skilled partner in the field of optical engineering, enabled us to meet all these complex requirements. We worked together with them to carefully select suitable plastics that would improve the components’ optical and mechanical properties while also complying with the tight tolerance requirements.

Rapid implementation despite plan changes
The project suffered a significant delay due to a last-minute hardware change in the sensor system made on what was actually supposed to be the tool production start date. This jeopardized the timely and prestigious launch of the innovative BERNINA 990.

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The components were manufactured using plastic injection molding

Thanks to an enormous display of commitment and several intense weeks at Tegra Medical, we were able to overhaul a total of three challenging new components in less than six weeks. The models were tested in several different simulations and plastic injection molding tools were designed, manufactured and sampled.

Thanks to our employees’ dedicated efforts, we were able to present all three components to BERNINA in time. Geographical proximity also let their project team check the assembly’s functionality at Tegra Medical’s premises and determine which steps needed to come next.

Partnership as a success factor
The project was completed in a very short time thanks to the open and excellent communication that exists between BERNINA and Tegra Medical, as well as the exceptional level of commitment on both sides. The components were manufactured in perfect quality from the outset, so that the new BERNINA 990 could be successfully launched on schedule and delivered to customers without delay. The new BISR technology now gives BERNINA a significant USP in the area of stitch regulation for home sewing machines.

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“Tegra Medical provided excellent service. They designed and manufactured the key components for us in a way that works both for plastics and tools – at lightning speed and in top quality,” says Alain Capt, System Architect at BERNINA.

This project highlighted the importance of the trusted partnership between BERNINA and us, a relationship that spans more than 30 years. All processes – from the components’ data release to the final evaluation of the final assembly – were performed together, in a spirit of partnership and with enormous efficiency.

Visit the Bernina website

Used technologies

Plastic Injection Molding Innovative molded parts made from plastic

Contact & Services

Bastian Hettich