For most DECT phones from Gigaset, FIM technology is used for color design. Even wood surfaces can be replicated and, through etching textures in the injection mold, achieve the desired tactile feel.

Every year, we process approximately 5,000 tonnes of steel into 50 million deep-drawn parts of the highest precision. We excel when things get particularly difficult. We produce even the most complicated parts with intricate geometries or complex shapes in consistent top quality. To do so, we use our own innovative process that combines the advantages of classic deep drawing with the possibilities of hydroforming.

POLYELAST® delivers extrude special semi-finished plastic products with exceptional, outstanding product characteristics in practice-orientated dimensions out PETP, PET, PA, POM, PS and PEEK, the result of professional competence that has grown over more than four decades. Under the trade name POLYELAST®, you will find a large, finely differentiated and practical product range with regards to measurements and choice of raw materials. We supply round bars, hollow rods, plates and filament characteristics tailored to your requirements. We make every effort in choosing raw materials and assuring quality to guarantee a high level of efficiency and application safety, alongside constant product quality, also for your client.

Our extensive range of demoulding products includes many tried and trusted products such as two-stage ejectors, components for controlling 3-plate moulds, and various demoulding aids.

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.

Autologous bone material plays an essential role in modern implantology for long-term stable rehabilitation. In oral surgery, a bone scraper is used to harvest this material – an instrument that enables the efficient and precise harvesting of autologous bone. Developed jointly with our customer and AGRODUR. Project contact: Thomas Bieber, CCE, Email: Thomas.Bieber@agrodur.de

Analyzing feasibility in injection molding is one thing. To optimize the entire process behind the drawing and making the right adjustments to the design is something completely different. Only if we make good decisions here will we be able to implement requirements permanently and economically. For example, we are able to design components for 3D printing so that they can be easily transferred to an injection molding concept later on.

From conception to a design ready for production At the concept stage, we use 3D design techniques to test whether our concepts can be replicated in a tool, and we achieve innovative results by pooling together all our knowledge of development, tool construction and production. If necessary, this will involve prototypes or small trial series using STL models and aluminium tools. This gives us valuable insights into subsequent series production. Our design department consists of five modern CAD workstations – this is where product designs and the corresponding injection moulding tool designs take shape. A further three CAM workstations are available to convert the CAD files into programmes for the tool machines.

From the idea to the finished injection-moulded part. Right from the initial development phase of a project, our team is working hard creating a production-ready design for your component, selecting the optimum material and developing the perfect tool design for your component. A uniform CAD-CAM system gives our designers and programmers the ideal platform for designing and constructing your tool. From day one, you have a contact partner who will see your project through from concept stage right through to series delivery.

The sight of a well-designed machine cover conveys the level of safety, cleanliness and structure in a company. Our designer windows make a significant contribution to occupational safety and appearance. Merk und Partner GmbH is your reliable partner for innovative, functional and aesthetically appealing design windows for your machine cladding.