Design

We take your specifications in the form of samples and drawings or simply your idea, and develop product solutions that are absolutely ideal for your purpose. In doing so, we pursue the objective of harmonising function with design to warrant low-cost production. After choosing the suitable material, we then design your component in cooperation with our partners on our modern CAD systems, taking account of all relevant factors.

Sample inspection

Initial samples suitable for installation are often needed in order to make progress also in the development of complex projects. We produce prototype moulds at short notice from lightweight materials for the production of the first parts which can then be used as a visual aid for the marketing department or as utility model in the development department. Large-scale mould production then begins swiftly after approval of the initial samples.

Toolmaking

CAD/CAM programming permits swift production of the vacuum moulds on CNC-controlled milling machines. Subsequent on-going developments are also easily implemented with mould inserts based on the existing programs.

Plastics

Each component must meet specific requirements. High impact strength, UV resistance, flexibility at low temperatures, food approval - these are just a few of the requirements for the physical properties of the material. Depending on these requirements, the most suitable material is selected from the possible materials. We process a wide range of thermoplastics. These include:

  • HD-PE (Polyethylen)
  • PP (Polypropylen)
  • PS (Polystyrol)
  • SB (Styrolbutadien)
  • ABS (Acrylnitril-Butadien-Styrol)
  • ASA (Acrylester-Styrol-Acrylnitril)
  • PMMA (Poly-Methyl-Methacrylat)
  • PC (Polycarbonat) 
  • PETG (Polyethylenterephthalat) 

In addition to the physical properties, the surface quality and the color can also be selected.

PE Polyethylene – a material with a future

...and with particularly outstanding properties under hard conditions in daily use. HD-PE is gently brought into shape using the vacuum forming method to preserve all the advantages.

  • Light: the specific weight is only 0.95 g/cm³
  • UV-resistant and weatherproof
  • Corrosion-resistant, durable
  • Shockproof and impact resistant, unbreakable between -50°C and +80°C
  • Dimensionally stable
  • Resilient
  • High chemical resistance
  • Food safe
  • Easy to store
  • Fully recyclable

Besides physical properties, the surface quality as well as the color hue can be chosen individually. 

Production

Deep Drawing

Vacuum forming is the heart of our production. More than 25 years of experience in processing thermoplastic materials make us your ideal partner. 6 vacuum forming machines produce parts up to a maximum blank surface area of 2,500 x 1,250 mm with a height of up to 600 mm. In this way, small parts can be produced in large quantities on multiple moulds just as quickly and flexibly as individual parts for trade-fairs.

Production steps

Step 1:

Heating panels heat the plastic sheet until the material becomes thermoplastic. During the heating phase, the material is constantly monitored by radiation pyrometers.

Step 2:

After the heating phase, the heating panels move back. The sealed mould chamber is filled with compressed air. The labile material yields to the pressure and is pre-stretched homogeneously. The aluminium mould then moves into the hemisphere.

Step 3:

As soon as the mould is in position, the air between the material and mould is extracted by vacuum so that the material assumes exactly the shape of the mould. Ventilators cool the material down again (monitored by radiation pyrometers), the clamping frame opens and the moulding can be removed. The production process is under complete control at all times. The system warrants the ideal material temperature.

 

Production steps
Production steps
Production steps

Milling

The vacuum moulded parts undergo post-processing on modern 5-axis CNC milling machines with a maximum machining width of 3,000 x 2,500 mm and 800 mm in height. This warrants reproducible part trimming from the first to the last part, also for follow-up orders. We can produce the necessary moulds quickly and economically in our own toolroom. We can also mill 2-dimensional parts such as frames, lettering or coverings, working to your specifications. Furthermore, parts produced elsewhere by injection moulding or rotation sintering can also be trimmed to the right size on our machines on a job-order basis.

Bending and welding

Our fully automatic bending machine can be used to produce parts with a length of up to 3,000 mm. Up to 5 bends are produced fully automatically according to the program. The next bending seam is already being heated up during the cooling phase. This permits particularly economical production particularly for box construction. Contact-free heating rails with upper and lower heating permit the production of small radii, while a heating sword in the upper heating circuit produces sharp angles with contact heating. The bent sheets are then brought to hot gas, butt welding or extruder welding machines to produce the finished boxes. This procedure is suitable both for individual parts and also for large series.
The Siemens S7 CNC control warrants reproducible production from the first to the xth part.

Assembly

Our assembly workstations are equipped with all the necessary manual tools to supply you with a component that can be used immediately. On the one hand, this includes additional procedures such as gluing, welding and hot embossing, and also on the other hand the actual finishing of a product by fitting add-on parts provided by the customer, for example. The services we provide extend right through to the product ready for sale.

Logistics

We offer flexible logistics solutions, catering individually to the needs of our customers. These include short-term delivery dates, different shipping addresses, interim storage and neutral deliveries in your name. The goods are labelled with all necessary details (e.g. barcodes).

Examples

Garages for robotic lawnmowers made from acrylic glass. (ABS/PMMA)
Protective housing made from ASA for sprockets for rotatable working platforms.
Paint panels made from ABS for the automotive industry.
Operating windows made from HD-PE (frame) and PMMA (window) for compressors.
Protective covers made from PS-UV for fittings.
Complete bumper buffer devices made from HD-PE for karts.
Protective grating made from HD-PE for coolers/radiators.
Vehicle cladding parts made from ABS.
Casings made from HD-PE for power distributors.

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