We supply customer-specific plastic injection molded parts and offer smallest precision parts, functional housings and complex multi-component injection-molded parts (2K / 3K processes, insert and outsert technology).
Plastics offer us a wide range of design options. By selecting suitable materials, surface finishes and creative designs, such molded parts can combine several key functions of a product at once. Starting with simple protection against dust and moisture, through product variations with specific printing and interchangeable inserts, to meeting special requirements such as ESD shielding.
We see ourselves as experts in the manufacture of high quality plastic injection molded parts and complex plastic assemblies. If necessary, we will accompany you from the first design approaches. Because especially in the construction phase, we can offer valuable assistance from a manufacturing point of view. In this way, adjustments towards the end of the design or costly changes to the tools can be avoided from the outset.
According to our production in Asia, we can offer injection molded parts for small and medium quantities at attractive conditions. We accompany you up to the serial delivery and take over the complete logistical handling.
Surface Treatment
In downstream processing steps, plastic surfaces are modified and refined in order to set defined properties for optics and haptics. The plastics are functionalized and refined for later use. Examples are the painting or printing of individual components, the laser marking of keyboards and the coatings for wear protection. We offer almost all treatments for plastic surfaces.
- pad & silk screen printing
- laser marking, engravings
- hot stamping
Paint
- glossy, matte, textured paint
- Soft-Touch Coating
Coatings & other finishing
- galvanic surface finishing
- PVD coatings
- EMC coatings
- powder coatings
- In-Mould Decoration (IMD)
Information on various surface technologies
Priting
Pad and silk screen printing technology are available for printing. With pad printing, the desired print motif is incorporated into a steel cliché and transferred to the surface by a silicone stamp. Compared to other printing techniques, the soft pressure stamp adapts very well to contoured surfaces. It is also possible to print on convex and concave surfaces. Color specifications: NCS, RAL, Pantone or color samples.
Laser Lettering
- With the help of laser inscription, a high-quality night design can be implemented on panels and buttons.
- Texts, engravings or the like can be worked into the workpieces using a laser beam.
IMD (In-Mould Decoration)
The IMD technology enables a large number of decor variants and reduces the production and decoration of the molded part to a single operation. An endless film, the carrier of the decoration, is automatically fed from the roll between the mold halves, positioned and fixed in the mold. After the mold is closed, the plastic is injected and immediately “welded” to the decorative layer that is detaching from the film to form a solid bond. Advantages of IMD:
- flexible color design
- high abrasion and scratch resistance
- Integration of closed LCD and LED windows
Painted housing shell and polished high-gloss matt combination
High-gloss-matt combination
Through the targeted use of structured areas alternating with polished accents, it is possible to design high-contrast design surfaces directly off the tool. The advantage of this surface technology is that further work steps such as painting, milling or foiling are no longer necessary. A cost-effective and reliable method, which can be implemented economically with medium quantities and represents an alternative to the IMD technology.
Soft-Touch Coating
For plastic parts made of ABS and PC we offer a soft-touch coating. This coating gives surfaces a velvety and soft feel and makes them insensitive to fingerprints and glare-free. Soft-touch coatings are used for example in automobile interiors.
PVD coating / vacuum coating
With vacuum coating or vacuum metallization, plastics are coated with a thin, metallic layer (2-5 μm) made of aluminum, copper, tin, gold, silver or others. The coating material is evaporated in a vacuum chamber and then condenses on the carrier material. The surface can be matt or high-gloss. EMC shielding can be implemented. Also wear-resistant corrosion protection is created. Compared to electroplating, PVD coating is cheaper and faster. The purity of the layers is very high and a selective coating is easy to implement.
Multi-component injection molding
Multi-component injection molding makes it possible to combine the positive properties of plastic and elastomer or metal in one component. This opens up a wide range of application examples.
Elastomer molded parts and plastic often appear together where the properties of a single component are insufficient. The hard component to absorb mechanical loads, the soft component as a seal, protection or cushioning. In a large number of cases, two separate components are designed for this. This leads to additional investments and effort in production and quality assurance, which can, however, be reduced by clever design in the development phase.
Metal and plastic parts can also be firmly connected using the insert technology . It is a process in which one or more components are connected to form a unit by being overmolded with plastic. Threaded sockets, screws, plug contacts or various inserts are placed in an injection molding tool and connected to the thermoplastic carrier material.
The outsert technique is similar to the insert technique; there, too, plastic elements are injected onto a metal carrier. The difference is that the metal insert has a larger volume than the plastic.
We offer proven manufacturing processes to combine several components in one product and have many years of experience both in plastic injection molding and in the manufacture of technically sophisticated silicone components. From this we draw the necessary synergies to develop solutions together with our customers.
We have also already implemented projects with 3 connected materials . Metal elements can be molded with plastic and at the same time equipped with an elastomer seal.
Individual housings, far removed from the standard all sorts
Individual housings offer the advantage of 100% adaptation to the needs of your input system. Shape, color and technical parameters can be realized exactly according to your requirements.
The multi-component injection molding process enables multi-colored plastic housings. Materials such as elastomers, seals or haptic properties are directly combined with the housing. This saves subsequent processing steps such as welding, gluing or vulcanizing.
In addition, we also offer suitable protective covers made of silicone or LSR of various hardnesses (Shore A40 – A70).
Protective covers made of silicone offer many advantages to a handheld device. In this way you protect the hardware from dirt and scratches, reduce damage in the event of a fall and the risk of slipping out of the hand.
The silicone covers are adapted to the existing housing and are highly customizable thanks to the option of OEM lettering and specific markings. Depending on the application, an additional PU coating can be applied.
If an existing plastic housing is to be supplemented with a silicone protective cover, we need an existing 3D file of the handheld device. Our engineers will then support you in designing a silicone case.
Production
Depending on the geometry, complexity and intended material of the molded part, optimized and individual temperature control and injection systems are designed right from the project start.
After the tool has been released for series production, the molded parts are injected. Injection molding machines with a clamping force of 70 to 1600 tons are possible.
According to our production in Asia, we can offer molded parts even for small and medium quantities at attractive conditions.
Tooling
Plastic injection molding tools are developed and manufactured in our certified production plants in Asia.
The construction of the tools is based on own development and many years of experience. Based on customer specifications a tool concept is created. The tool design is carried out in according to international standard parts and in accordance with the HASCO industry standard.
During this development process, we offer a Mould-Flow-Analysis and provide technical advice on surface qualities, wear-resistant tool parts, temperature-controlled mold-injection systems, etc.
Tools will be finally created after the construction approval and later shipped to customers.
- customized hot runner systems: HASCO, Yudo, Husky, DME, Mold Master, Incoe, Synventive, Ewikon, Parker, Staubli
- pressing tools (SMC technology)
- multiple injection molding (up to 128 cavities)
- stacking tools (with 2 parting planes)
- gas internal pressure tools
- foil Injection Tools (IMD)
- insert tools
- 1K and 2K injection molds
- prototyping
3D Prototyping
In the field of prototyping via 3D printing, we have been working with well-known providers for years. To expand our range of services, we now offer prototyping in-house.
With the Stratasys F370 3D printer, we produce prototypes and devices from real plastic up to a size of 355 x 254 x 355mm, with an accuracy of ± 0.2 mm. In addition to the materials ABS, ASA, PLA and TPU, the materials PC-ABS, static dissipative ABS-ESD7 as well as tough and chemical-resistant PA6.6 MF07 (Diran) can be processed.
With 2 heads the F370 is able to print the product material and the soluble support structures at the same time. In a subsequent ultrasonic bath, the support structures are washed out without manual removal.
We also work with a 3D printer using stereolithography technology (SLA). With SLA technology, liquid resin is cured in layers using a UV laser. The individual layer thickness can be varied in the range of 25 µm – 100 µm.
Example of a prototype creation in a 3D printer
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