Development

We offer everything from one source, from the initial concept for a plastic-suited part geometry up to the definitive mold design.

Consulting And Project Planning

We will support you in your choice of the correct manufacturing process, in the development of the perfect mold concept and in the definition of the necessary facilities.

Design

Thanks to our in house engineering, we are able to work together directly, are in close contact with production and can thus find the best solutions.

Programming

All programs are created from the 3D model. The respective strategies, technologies and programs are sent directly to the machines. This can reduce the lead time and minimize the risk of errors.

Milling

This processing constitutes a central process for us. We process mold units, electrodes and mold inserts in soft and hardened steel. We use 5-axis machines with robots.

Machining

Our Matec 40HV has two machining zones, each with a rotary table. Parts up to one meter can be processed on this machine from 5 sides.

Hard Milling

On our DMG HSC 65, we premachine our workpieces for hardening and finish them after hardening to the finished dimensions. Using the tool changer with 180 tools, we are able to define sufficient standard and replacement tools to ensure that long, complex machining processes can be performed unmanned.

Electrode Manufacture

We produce the electrodes on our DMG HSC 20. Maximum surface quality and the finest contours can be produced with linear axles and a spindle with a maximum of 42,000 rpm. Our internally-developed pick and place robot with 220 electrode trays enables maximum autonomy.

EDM

EDM is the most important process in the making of punching tools and injection molds. It is almost impossible to produce complex geometries without this procedure. In order to be economical with this relatively slow process, we create an environment, so that the highest runtimes possible can be achieved with as little personnel expenditure as possible.

Die Sinking EDM

Our EDM cells are integrated in the production process such that the die sinking EDM and measurement programs are created at electrode engineering and can then be used directly on the production cell. The measured offset data is of course automatically included in the EDM process. With the 10 workpiece pallets and the 220 electrodes in the pick and place robot, we can guarantee 24-hour operation with our Zimmer&Kreim Genius eroding machine.

Wire Cut EDM

Our Robofil 6050 TW from GF enables a high degree of flexibility as regards the parts to be machined. We can achieve this flexibility with the job manager, which has been developed to meet our own expectations, including the sequence of processing steps. Together with the integrated measuring machine, we also pursued a consistent path towards automation with wire cut EDM.

Lasertexturing

Machining parts using laser technology offers innovative options. In addition to classic labeling, texturing, microstructuring, marking and engraving is also possible via laser ablation. Our areas of expertise include complex and filigree machining.

https://youtu.be/

Laser Engraving

Our lasers enable engravings and markings to be realized efficiently. Using the precise laser process means that complex production procedures such as sink erosion or even profile grinding can be replaced. Our laser systems have 5 axes and programming is carried out directly from a 3D model. Our capabilities thus extend well beyond simple laser marking.

Laser Texturing

Texturing and microstructuring offer a number of design-related benefits compared with other procedures. Surface design can be chosen as desired: abrasive blasting and erosion structures, etched structures, as well as detailed and complex surface machining are possible. The replacement of chemical etching processes is also interesting from an ecological point of view, in addition to the achievable reproducibility. The adaptation of any optical, haptic or tribological structure to a freeform surface is no problem using a fully-digital process. More… (only in German)

Grinding

Grinding is an essential process where maximum precision standards are required. Even if other production processes continue to grow in significance in many areas, we will focus specifically on grinding in future.

Flat Grinding/Profile Grinding

Our high-performance grinding machines from various manufacturers enable us to produce precise workpieces that we can then install in our complex molds and punch tools.

Jig Grinding

When other procedures prove inadequate, we use coordinate grinding. Optimum results can be achieved with extensive knowledge and skill.

Assembly

A substantial part of the quality of the mold is influenced in assembly. These final work steps are decisive for the quality of the parts to be produced and the service life of the mold.

Polishing

The surface of the plastic part, the demolding and the lifetime are impacted by polishing. This work, some of which is performed manually, requires a great deal of patience and skills.

Final Assembly

Assembling the exact individual parts into a well functioning whole requires considerable experience and skills.

Quality Management

The quality is determined using regulated production processes and checking these processes in measurement procedures. This interaction is crucial for the precise and cost-effective manufacture of our products.

3D Coordinate Measurement

The 3D coordinate measurement machines are used for quality control in ongoing production and to preset parts and electrodes for automated production. If required, measurement reports can be created for individual parts.

Optical Measurement

We are also able to measure the geometries optically. This is particularly suitable for small parts or 2D geometries.