Fertigungskompetenz im Thermoformen

[Bitte in "English" uebersetzen:] Werkzeug und Tiefziehteil

Equipped for Every Process Step

Our modern machinery covers everything your product needs - from CAD/CAM programming for toolmaking and thermoforming systems to post-processing with CNC machining centers. For bending, welding, and laser work, we have a range of machines and automated systems at our disposal. And wherever automation is not possible, our well-equipped assembly stations and experienced specialists ensure precise manual workmanship.

Thermoforming Production Process

Vacuum forming has established itself as a recognized plastic processing method alongside injection molding. There are two types of thermoforming: positive thermoforming and negative thermoforming.

Positive thermoforming:
In the positive process, the plastic sheet is placed over the tool and drawn onto it by vacuum. The outside surface is not touched, preserving the surface quality for visible parts. The inside is the tool-contact side, ensuring precise contours. Later changes in material thickness build outward and do not affect inner dimensional accuracy or assembly.
Negative thermoforming:
In the negative process, the heated plastic sheet is drawn into the tool by vacuum. Here, the tool-contact side is usually also the visible surface of the part. This allows coarse structures, markings, and logos to be displayed directly on the surface. Negative thermoforming is often used when the outer contour must precisely align with other components. Changes in material thickness build inward. The disadvantage lies in the higher tooling costs.

What are the advantages of thermoforming?

Cost-effective: Low tooling costs, since usually only one mold half is required - even for very thick- or thin-walled parts.
Wide variety of shapes: Multi-cavity molds reduce unit costs at higher volumes. Also enables the production of complex and large forms with high precision.
Flexible for design changes: Due to the simple mold structure, modifications can be made at any time.
Versatile materials: Broad range of thermoplastics suitable for forming. Finished parts can feature high-quality appearance with colored material, glossy or grained surfaces - no additional painting required.
Recyclable: Thermoplastic materials used are recyclable, making the process environmentally friendly.
Fast production: Short setup times and efficient processes allow for rapid manufacturing.

Example Positive Thermoforming

[Bitte in "English" uebersetzen:] Kunststoffplatte wird durch Heizfelder erwärmt bis sich das Material thermoplastisch verhält. Während der Heizphase steht das Material unter ständiger Beobachtung durch Strahlungspyrometer.

Step 1:
The plastic sheet is heated by radiant panels until the material reaches a thermoplastic state. During the heating phase, the material is continuously monitored by radiation pyrometers.

[Bitte in "English" uebersetzen:] Nach der Aufheizphase fahren die Heizfelder nach hinten zurück. In den abgedichteten Formenraum wird Druckluft gegeben. Das labile Material gibt dem Druck nach und wird homogen vorgestreckt. Anschließend fährt die Aluminiumform in die Halbkugel ein.

Step 2:
After heating, the panels retract. Compressed air is introduced into the sealed mold chamber, causing the softened material to stretch evenly. The aluminum mold then moves into the pre-stretched dome.

[Bitte in "English" uebersetzen:] Formteil kann entnommen werden

Step 3:
Once the mold is in position, vacuum removes the air between the material and the mold, so the sheet precisely reproduces the mold contour. Fans then cool the material (again monitored by radiation pyrometers). The clamping frame opens, and the molded part can be removed. At all times, the process remains visible, ensuring optimal material temperature and consistent quality.

Combination of Positive and Negative Thermoforming

For assemblies, a combination of both processes is often used. In this example, the inner shell of a door panel is formed negatively, while the outer shell is formed positively. After contour CNC milling, both parts are bonded together. By combining the two manufacturing methods, bonding of the tool-contact sides ensures precise fit.

[Bitte in "English" uebersetzen:] Herstellung eines Tiefziehwerkzeugs

Toolmaking

Regional Partnerships

The production of thermoforming tools is carried out on state-of-the-art CNC milling machines, enabling fast and precise implementation of CAD/CAM programs. For this, we work closely with regional partners who possess the necessary expertise and advanced machinery. These partnerships ensure high-quality manufacturing and flexibility in meeting individual customer requirements, even for complex geometries. Another advantage of this approach is the straightforward implementation of later improvements. Based on existing programs, tool inserts can be used to easily make adjustments or optimizations to meet current requirements.

In-house Production

For the fast and cost-efficient production of milling fixtures, we rely on our own manufacturing capabilities. We use high-quality materials such as wood and cast resin, which are ideally suited for this purpose. Wood allows easy handling and rapid implementation, while cast resin offers versatility through its flexibility and stability. Thanks to our in-house production, we can respond flexibly to customer needs, ensure short delivery times, and keep costs down.

Flexible Assembly, Processing, and Finishing

Our assembly stations are fully equipped with the necessary tools to deliver functional, high-quality components. In addition to standard assembly steps, we also offer further processing options such as bonding, welding, and laser marking to ensure the functionality and durability of your products.

We also handle the finishing of your products through professional assembly - for example, by installing customer-supplied add-on parts or additional components. Our goal is to cover the entire manufacturing process seamlessly - from single-part assembly to the ready-to-sell end product.

This way, we guarantee on-time delivery and the highest quality.

[Bitte in "English" uebersetzen:] Komplettansicht einer Maschine zum tiefziehen von Kunststoffteilen

[Bitte in "English" uebersetzen:] CNC Fraesmaschine

Machinery

Our machinery includes six thermoforming systems from GEISS (Sesslach), featuring the latest servo-motor control, central blower, and touchscreen interface. We can process sheet sizes ranging from 500 x 400 mm up to 2,500 x 1,250 mm and material thicknesses from 2 mm to 12 mm.

For post-processing, we operate five 5-axis CNC machining centers from HG Grimme SysTech (Wiedergeltingen). These range from rotary table systems for small parts to portal and gantry milling machines with tandem tables for large parts up to 3,000 x 2,000 mm, equipped with 12-position tool changers.

In our bending and welding department, we use a 3,000 mm fully automatic bending machine from Ingenia (Altlay) and two manual machines up to 1,000 mm from Reichel (Nieder-Olm). For joining components, we employ various extruder, ultrasonic, and hot-gas welding devices, as well as a butt-welding machine.

A laser system enables precise part marking, while various measuring systems, including a Hexagon 3D measuring arm, ensure compliance with specified tolerances.

Logistics

Tailored to the needs of our customers, we offer sustainable and flexible logistics solutions. These include short delivery times, multiple shipping addresses, interim storage, and neutral deliveries under your name. Products are labeled with all required information (e.g., barcodes).

More Sustainability with ROWEKO

You have further questions? We will be glad to advise you! +49 (0) 7133 228808-0 info@roweko.de