Process reliability, efficient, custom-made – plastic designs from Keune & Lauber
Many of our customers already know exactly how their end product should look and what characteristics it should have. What is usually missing is the product and process development required to put the product into mass production.
Development partner right from the start
There is always an idea at the beginning of each injection molded product which we want to develop further step-by-step and ultimately make it a reality. We create CAD files according to your sketches, drawing, models or templates which help us to realize your individual plastic part according to your ideas and wishes. Thanks to their extensive experience in the field of plastics technology, our plastic construction experts know exactly which injection molding method and which materials would be best for the manufacturing of your plastic parts. Supported by the 2D and 3D CAD systems, our team is always there to help you throughout the entire project – from the development, to the mass production and right through to the finishing of your completed plastic products and their prompt delivery. The earlier that you involve us in your project, the quicker and more efficiently we can make your project successful together. Whether the idea has only existed in your head until now, or if you come to us with a sketch, a specification sheet or a handmade model, we will take on your demands and wishes in a targeted and systematic way and will fully dedicate ourselves to developing a solution for you.
Our know-how for your components
If someone has too little experience in constructing components and injection mold tools designed for plastic, they may do something wrong. In the worst-case scenario, a plastic design which has not been thought through could cause you to lose lots of money and valuable time. So that at the end of the development and production process high-quality plastic products which completely fulfil their function are produced, the following plastic technology rules must be observed when designing your plastic parts and the relevant injection mold tools:
Lowest possible wall thickness
Determining the optimal wall thickness is an important constructive challenge with many components, as the lowest weight possible must be combined with a good level of workability and the required stability. On the one hand, a low wall strength results in a significant saving in terms of material and weight, and on the other, it results in shorter cooling times.
The wall thicknesses should be as even as possible over the entire plastic component
With consistent wall thicknesses, air pockets, surface defects and warping can all be avoided. As it essentially comes down to a uniform cooling, it may be necessary to adjust the wall thickness on edges and corners.
Avoidance of mass accumulations
Mass accumulations as a result of local variations in the wall strength of the components can lead to individual areas cooling at different times or significant variations in shrinking during the cooling. As a result, sink marks, which are particularly visible on smooth surfaces, may occur. Therefore, the wall thickness must be taken into consideration and designed accordingly if any reinforcement ribs and similar designs are added.
Avoidance of weld lines
Weld lines form where the melted material from the injection molding of several sides joins together. As these lines are a mechanical weak point and an optical imperfection, they should be put under as little strain as possible by ensuring an appropriate design of the flow channels and should be placed in an area which is not visible. As specialists in plastics technology, we provide an extensive service when it comes to plastic design and injection molding. It includes comprehensive support throughout the entire design phase, a functional choice of material and the demonstration of the most cost-effective processing steps.
Simulation-supported construction for cost-optimized development
Until the first plastic products come out of the injection molding machine, there are many necessary steps which must be planned in advance depending on the material used. With the help of simulation software, we can virtually predict construction and manufacturing problems and eliminate them before the actual injection molding takes place. This enables us to shorten product cycles and to avoid having to make any changes to tools at a later date. You profit from lower costs and increased process reliability. Our simulations, which are done as part of the plastic design, take place during the entire injection molding process. These simulations include, amongst others:
- Design and optimization of the mold tempering,
- Filling simulation,
- Shrinking and warping behavior,
- Holding pressure phase.
Working with high-performance construction and development tools helps us to bring new plastic products into production quicker without time-consuming project times, costlier prototypes and potential production defects. By getting us involved early on in the planning phase, it is more likely that you will be able to avoid any problems right from the beginning and will be able to make the injection molding more suitable for the plastic and therefore more efficient overall.