Experts in
Plastics Technology.
You have the idea. We have the technology. Together, we shape the future.
Toolmaking
We develop precise and durable tools that are perfectly tailored to your requirements in plastic processing.
Toolmaking Processes
Tool Design
Using state-of-the-art software like Think and CATIA, we create complete designs with manufacturing-ready bill of materials, individual part drawings and calculations for warping and air inclusions. The quality of the components is our top priority.
Grinding
We grind workpieces on state-of-the-art CNC grinding machines according to drawings and CAD data with the highest precision.
Wire EDM (Electrical Discharge Machining)
Wire EDM is the key technology of our company. Experienced employees cut intricate contours with high precision and exceptional quality from various materials.
Sinker EDM (Electrical Discharge Machining)
With state-of-the-art sinker EDM machines, we erode intricate contours with the highest precision. The pre-setting of workpieces and graphite electrodes takes place externally on a measuring machine and is then loaded onto the sinker EDM machine with automation. Here, running times of up to 23 hours a day are achieved.
Milling
In CNC milling, we use the data from the tool design to create the CNC programs. After that, we mill high-precision workpieces on our 5-axis milling machine with automation.
Tool Assembly
Experienced employees assemble the parts pre-fabricated by the machine operators into an injection molding tool. Accuracy and quality are the top priorities.
Plastic Injection Molding
Using state-of-the-art machines, we manufacture components with complex geometries and fine structures with the highest precision.
Plastic Injection Molding Technologies
Compact and Multi-Component Injection Molding
Compact injection molding with a single component (1K) is a technology for producing functional plastic parts with precise dimensions in a wide variety of products. Multi-component injection molding (e.g., 2K for two components) enables the cost-effective production of plastic parts made from different materials (e.g., hard-soft combinations and different colors) using a single injection molding machine. The advantage lies in saving additional assembly steps.
Precision Injection Molding
Precision injection molding enables the production of products in various sizes and with varying degrees of accuracy.
MuCell® Injection Molding Process
The MuCell® technology for injection molding microcellular foam from thermoplastics offers unique potential for cost savings compared to conventional injection molding. The combination of lower density and reduced cycle times often results in savings of over 15% in cycle time, material, and weight. In terms of quality, MuCell® parts are distinguished by higher shape stability compared to conventionally manufactured components and simultaneously eliminate sink marks.
Chemical Foaming
In chemical foaming, a blowing agent is added to the plastic. This chemical additive decomposes during the plasticization of the material, releasing gas as the temperature rises. The gas dissolves in the melt while maintaining a minimum pressure, creating a foam structure in the plastic.
Silicone Injection Molding
Silicones are high-quality materials that acquire their specific properties through a specialized processing method. The processing is carried out on injection molding machines designed for this purpose, with a cool cylinder module and a heated mold.
Silicone Injection Molding Technology
Applications
Silicone injection-molded components offer versatile applications due to their universal material properties. One of the key features is their excellent compression set. Parts that are deformed at high temperatures and prolonged exposure will return to their original shape once the external pressure is removed, showing minimal compression set.
LSR (Liquid Silicone Rubber) is particularly suitable for applications with the following requirements:
- Sealing against water and dirt (automotive technology, medical technology, fuel cells, etc.)
- Noise damping (automotive technology, etc.)
- Vibration damping (automotive technology, medical technology, etc.)
- Insulation of electrical components (automotive technology, electrical engineering, etc.)
- Physiological safety (medical technology, hygiene products, etc.)
- Sterilizable due to high temperature resistance (medical technology, etc.)
Processing
In the injection molding of liquid silicone (LSR – Liquid Silicone Rubber), two low-viscosity components are mixed in a 1:1 ratio and brought into reaction.
The two addition-curing components are supplied to a mixing block under pressure using a multi-component mixing and dosing system. To prevent early vulcanization in the barrel of the injection molding machine, the special LSR screw unit is temperature-controlled to around 20–25°C. Depending on the screw diameter and thread pitch, dynamic mixing occurs in the barrel. From the barrel, the LSR is injected into the mold via a cold runner, which is heated to 170 to 220°C. The high temperatures in the mold cause the LSR to cure in a short time.
Tooling Technology
Due to the low viscosity – LSR flows like water before curing – and the high injection pressures, the injection molds must be manufactured with very high precision. Tolerances that are too large can lead to burrs and flash formation.
Since LSR cannot be re-melted or recycled after curing, we aim to avoid runner systems and instead bring the silicone directly to the mold cavities via cold runners. The cold runner is an extension of the injection unit, where the LSR should remain as cold as possible. Curing must only begin in the cavity, which means that the thermal separation between the cold runner and the mold cavity is a critical point.
Due to the soft and unstable structure of silicone parts, there are almost no limits to shaping. Many undercuts, which in classic thermoplastic injection molding are usually removed by sliders, can be achieved in LSR processing through forced ejection. Various handling devices are used for ejection, blowing, or brushing the parts.
Foaming
Using advanced processes, we provide precise and reliable solutions for single-component and two-component polyurethane foaming, ideal for a wide range of applications and requirements.
Foaming Technologies
1K PU-Foaming
In single-component polyurethane foaming, the mixing and chemical reaction of the base material with the blowing agent, which is typically required in 2K systems, is unnecessary. This eliminates dosage errors or fluctuations. Even small amounts can be dosed safely and reproducibly. In the manufacturing process, the (viscous) liquid material is directly applied as a foam bead onto the component.
2K PU-Foaming
The reaction of 2K sealing foams is initiated by mixing the A-component (resin) and B-component (hardener). The result is a chemical reaction with a consistent course under room temperature conditions. The applied material then foams into a uniform seal. The seal is directly foamed onto the component.
Welding
With innovative welding technologies, we offer high-strength and homogeneous bonds for thermoplastic plastics that meet the highest standards of quality and reliability.
Welding Technologies
Hot-Gas-Welding
Hot gas welding is a patented process used to achieve a high-strength, homogeneous, and particle-free thermal welding of high-performance plastics.
Heater Element Welding
Heater element welding is a process used to join thermoplastic materials by using a heated element to melt the joining surfaces. The heated element is applied to the material, causing it to soften and form a strong bond when the element is removed and the materials cool down. This method is commonly used for welding plastic parts in industries such as automotive, medical, and packaging, providing reliable, durable joints.
Rotary Friction Welding
The process of rotary friction welding is suitable for joining rotationally symmetrical parts and has proven to be an ideal joining technique for the production of so-called mass parts. In this process, the heat required to plastify the material is generated by interfacial friction between the two parts. The part to be welded is set into a rotating motion, while the second part is firmly fixed and locked in place.
Ultrasonic Welding
In ultrasonic welding, the heat required for plasticizing is generated by converting ultrasonic vibrations into mechanical vibrations, which are applied to the workpiece through the sonotrode with a specific pressure. This process is suitable only for joining thermoplastics using friction welding.
Assembly
With advanced assembly and testing technologies, we provide customized solutions for precise and reliable manufacturing processes, from optical inspection to highly accurate assembly in large quantities.
Assembly and Testing Technologies
Camera Inspection Technology
Optical inspection through camera systems (e.g., for missing parts, geometries, external dimensions or grid measurements).
Leak Testing
Leak testing is performed to verify the tightness using vacuum and/or overpressure methods.
Robot Automation
Custom machines and assembly systems for high-precision, accurate assembly tasks.
Rotary Table Assembly Systems
The movement of the workpieces in these systems is centrally controlled, making them cost-effective. The workpieces are only moved at the positions where necessary.
Assembly Lines
We use assembly lines to carry out semi-automated or fully automated mechanical assemblies for large volumes and low cycle times, ensuring high repeatability and precision.
Manual Workstations
Traditional manual assembly is now primarily used for small series or prototype production.
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