toolcraft AG
About us
toolcraft is a pioneer in pioneering technologies such as additive manufacturing and the construction of customised turnkey robot solutions. Innovative processes are tested in engineering and brought to series production readiness. As a partner for complete solutions, toolcraft offers the entire process chain from the initial idea to production and qualified parts in the areas of injection moulding + mould making, CNC machining and additive manufacturing. Its customers include market leaders in the semiconductor industry, medical technology, aerospace, special machine construction, motorsport and automotive.
Products & services
Binocular photorefraction – Precision preventive care
the starting point – New partner for new model series Plusoptix needed support for producing a new series of camera parts for children’s eye tests(Photorefractors). They sought a manufacturing partner who could also advise on design. Due to toolcraft’s long-standing expertise in mould making and injection moulding, Plusoptix chose toolcraft. The Challenge – Guaranteeing optimum functionality In mould making, a decision was needed between undercut sliders and forced demoulding. Forced demoulding was chosen to reduce costs and prevent contamination during moulding. Parts also had to be free of flow marks and sink marks. Precise fit was critical for screw and snap functions. The Approach – Excellent advice from start to finish An interdisciplinary team from mould making and injection moulding was formed. toolcraft advised on plastic-compatible design, built three moulds, and produced the parts. Quality control was performed using optical measurement (GOM). The Result – Optimization and reduction toolcraft optimized the battery cover geometry, eliminating an assembly step and reducing manufacturing costs. Customer requirements were fully met, enabling the new model series to launch as planned.
Dental applications – Innovation meets quality
The starting point – Improving material, design and functionality To optimize minimally invasive caries treatment using highly fluid infiltrating resin, DMG sought a new manufacturing partner to redesign the existing syringe and its seals. The goal was to find a new material for the sealing plug, redesign the seal, and improve functionality. DMG contacted toolcraft for development and component manufacturing. The Challenge – Meeting highest standards for medical parts The material had to be compatible with the infiltrating fluid and provide the required Shore hardness for sealing. Tight tolerances for fits were critical. The biggest challenge was thermal management in 2K injection moulding due to the large temperature difference between the PBT hard and TPE soft components. Cycle time optimization and maintaining high medical quality standards were also key. The Approach – Comprehensive consultation and support every step of the way Consulting on material selection and design, developing designs for four parts in three plastics (2K PBT, TPE, 1K LSR), building two moulds and production of the injection moulded parts. Components were robotically removed, singulated, and quality checked (including CT scanning). A mounting fixture was designed and built to assemble the parts. The Result – Automated manufacturing and quality assurance Thanks to toolcraft’s expertise, production, assembly and CT-based inspection were automated and components optimized. From design to production, teams from toolmaking, injection moulding and robotics ensured seamless customer support.
Mould with an optimies topology
The Starting Point – Conventional mould for plastic injection moulding The existing mould, made of mould inserts, plates, clamping plates, and standard parts, measures 125 x 125 x 130 mm and weighs about 60 kg. The project aimed to optimize the injection moulding process by reducing cycle time and simplifying the assembly complexity. Using additive manufacturing, the mould was redesigned and its topology optimized according to loads and requirements. The result: a smaller, lighter mould with integrated conformal cooling. The Challenge – Maintaining functionality During topology optimization, critical functional surfaces like mold half alignment, ejector system position, and machine interface had to be preserved. The design also accounted for subsequent clamping for CNC post-processing. Distortion during metal 3D printing posed another challenge. Optimal part orientation, support design, and process simulations helped detect distortion early and avoid scrap. The “first time right” principle is key here. The Approach – End-to-end process with Siemens NX From redesign, material selection, and cooling integration to FEM and cooling simulations, data prep, print simulation, metal 3D printing, finishing, and CNC machining, the process was digitally mapped and efficiently executed. Quality control was optical and tactile. The mould was then successfully deployed in production. The Result – A step toward the future of mould making The new 3D-printed mould features smaller dimensions and nearly 50% less mass. Reduced weight simplifies installation and lowers machine clamping forces. Thanks to conformal cooling, cycle times decreased by 30% while maintaining part quality.
Micro-plastic Components - at the push of a button
The starting point - Design follows process A cerumen filter that can be replaced independently by the user increases the service life and acoustic performance of modern hearing aids. The objective was to develop a filter system suitable for fully automated manufacturing - cost-effective, precise and ready for series production. The filter, smaller than a grain of granulate, is manufactured using micro injection moulding and stands out due to its filigree design and long service life. The Challenge - Bringing the smallest of parts into full-size view Implementation placed the highest demands on mould making, automation and the handling of micro components. Particularly challenging were reliable gripping, singulation and inspection of the filters within the defined cycle time. The process was complemented by camera-based inspection, laser micrometer technology and laser marking of the packaging. Tight delivery schedules as well as material changes - including the switch to glass-fiber-reinforced POM - further increased complexity. The Approach - Perfectly combined An interdisciplinary team from mould making, robotics and injection moulding developed an end-to-end production concept, ranging from feasibility studies and design optimization to VR simulation and the parallel implementation of tooling and automation. Quality assurance was carried out continuously using sample-based CT measurements. The Results - A world of sound Despite a fixed series launch date and ongoing material and design adjustments, the project was successfully realized together with the customer. The high time pressure required the parallel implementation of two production lines - both went into series production on schedule. Today, the cerumen filter system runs fully automated and reliably in production. It exemplifies the successful combination of micro injection molding, high-precision automation and close development partnership.