Cable routing area: Automotive insert molding / metal overmolding

Plastic-metal composites combine the functionality of metallic materials with the design possibilities of plastics. We are committed to integrating metallic components into hybrid plastic molded parts - insert technology is a core business. Many years of experience and special know-how convince our demanding customers when overmolding - bushings, threaded inserts and shafts for mechanical fixation, - lead frames, stamped grids and circuit boards for electrical functions, - magnetic carriers and stators for sensor and drive technology. We achieve a sufficiently high level of vertical integration by linking upstream and downstream bending and punching operations as well as optical and electrical tests.

With over 25 years of expertise in the production of individual colour masterbatches, GRAFE meets every challenge beyond the standard range. Be it special customer materials to be used as carriers, individual effect colours or special production processes - we implement the wishes of our customers. The ultra-modern technological equipment of our pilot plant enables a precisely fitting preliminary simulation of the products, especially in the injection moulding process, film extrusion and especially in blow moulding (2-layer system). This year, 4 exciting theme projects provided the necessary inspiration for the design departments! COLOR FOOD ORIENT CULTURE INTERIOR INSPIRATION NATIVE CULTURE

Automation on principle? Not with us. Sometimes manual production is the better choice for injection molded parts. Automatically overmolding various inserts? That's only worthwhile for large quantities. In the prototype stage with small production runs, we therefore do without complete automation and instead rely on insert technology in injection molding. The inserts are placed in the molds by hand and then overmolded - insert technology is a high-quality and cost-effective process for smaller quantities.

Create the best conditions for ideal thermal insulation of your moulds. In addition to a comprehensive range of standard insulation boards in different designs, we also offer custom-made boards precision-machined as per drawing.

Weiss produces sensor housings using the 2K process for a manufacturer of tire pressure monitoring systems. Stamped and bent parts are also integrated into the housing as transmitting antennas. They pass on the measurement data via radio. THE TASK The task was to design and manufacture a housing for the sensors housed in the tire. The specifications included a service life of five years and thus permanent protection of the sensitive measuring electronics, access to the pressure sensor and the integration of the antenna with which the measurement data is transmitted to the telematics unit. THE SOLUTION The production concept developed by Weiss begins not only with the plastic granules, but also with a delicate stamped and bent part. It serves as an antenna that sends the sensor signals to the telematics unit. It is automatically separated and placed by a robot in a 2K tool that is equipped with a turn-turn device. The 2K injection molding system first encapsulates the punched-bent part with a PBT, which the actual sensor housing is made of, and in the second process step with a soft TPE, which closes the assembly openings and forms a seal. After an automated in-line test, the housings are placed - again automatically - in the transport packaging. SPECIAL FEATURE Two automated in-line tests are part of the production process. One is to ensure that the hole that ensures air flow through the sensor is present and of sufficient size. The presence of the antenna in the sensor housing is also checked. The control concept is also unconventional: As a master, the robot determines the cycle of the injection molding machine, and the control allows both a start-up phase and continuous production in smaller quantities. The metal parts are then inserted into the tools by hand.

Here you can download the short introduction of the institute.