Please do not hesitate to contact us with questions and/ or special requirements. Please send us an email or call us during our business hours at +49 3722 6316-0. We look forward to hearing from you. Click here for our contacts page.
Efficient Tooling Through Modern Simulation Technologies
A short lead time to the finished production tool is one of the most important factors for success in tool and prototype manufacturing today. That is why we consistently use modern software solutions to define optimal manufacturing processes early on. Through the targeted use of forming simulations, we can not only analyze processes but also improve them at an early stage.
For example, springback is integrated into the active parts of the tool in advance, significantly reducing the need for subsequent adjustments. This saves not only time but also costs, while simultaneously improving the quality of the components.
Precise Manufacturing and Assembly in Our In-House Tool Shop
For mechanical machining, all individual tool components are manufactured entirely in our in-house production facility. Subsequently, all components are carefully prepared for assembly to ensure a smooth process.
Our experienced toolmakers precisely coordinate all individual parts, ensuring that the tools function accurately and reliably over the long term. The tools are then extensively tested on our in-house test presses and gradually optimized.
Once all requirements are met, our quality assurance team provides final approval before the finished tool enters series production.
Services offered by our tool- and die-making department – overview
Progressive Die Tools in Modern Toolmaking
When large production volumes are required and component costs need to be kept as low as possible, a progressive die tool is the optimal solution in toolmaking. This is because, particularly in mass production, this design not only enables high efficiency but also consistently high quality.
Complexity and Key Influencing Factors
However, the design of progressive dies is usually very complex, as numerous factors must be taken into account. These include, among other things, the exact positioning of the sheet metal strip, the potential deformation of the scrap material, and the precise location of the component in each individual station. Only when all these aspects are optimally coordinated can the desired result be reliably achieved.
How a Progressive Die Works
A progressive die consists of several stations that perform various cutting and forming processes either simultaneously or sequentially. During this process, the sheet metal strip is continuously fed through the die, resulting in a finished component at the end of the run.
The sheet metal strip is typically held in place with precision using positioning elements. This ensures that all stations work in precise coordination with one another and that the component is manufactured exactly to specification. Finally, a cutting punch at the end of the die ensures that the finished component is cleanly separated from the scrap.
Advantages of progressive dies
The greatest advantages of a progressive die lie primarily in high productivity and significant cost reduction for large production volumes. Furthermore, this technology enables stable and repeatable manufacturing, making it particularly suitable for industrial series production.
Transfer Dies in Toolmaking for Complex Components
When large sheet metal parts with particularly intricate or complex shapes are required, a transfer die is often the better choice in toolmaking. Compared to progressive dies, this design allows for significantly more flexible production, especially when dealing with challenging geometries.
Structure and Function of Transfer Dies
A transfer die consists of several separate stations that can operate either individually or in tandem. Unlike the traditional sheet metal strip process, however, this method works with individual blanks. These are transported from station to station using grippers and a transfer mechanism coupled to the press.
This not only ensures precise positioning but also enables controlled processing at every single stage of production.
Applications and Advantages of Transfer Technology
The transfer manufacturing process is used in particular when components are too complex to be produced from a continuous sheet metal strip. This process offers significant advantages, especially for large-surface or heavily formed parts, as the individual processing steps can be optimized independently of one another.
Consequently, transfer die manufacturing is particularly well-suited for demanding components that require both precision and flexibility.
Fine-blanking dies for the highest cutting quality
When components require a smooth-cut ratio of up to 100%, however, it is necessary to use a fine-blanking die in toolmaking. This process enables particularly clean cut edges as well as high dimensional accuracy.
This not only improves the quality of the components but also significantly reduces post-processing, which in turn saves time and costs.
Fine-blanking tools in toolmaking for maximum precision
Unlike conventional punching, the use of a fine-blanking tool in toolmaking significantly optimizes the cutting process through a specialized tool design. This involves, among other things, a ring-shaped cutting edge and a specially designed press, resulting in an exceptionally precise cut.
Optimized cutting process through specialized tooling technology
This unique combination not only stabilizes the cutting process but also specifically improves it. As a result, up to 100% of the cut surfaces on the fine-blanked parts can be smooth—even with thicker sheet metal.
This results in exceptionally high component quality while simultaneously increasing process reliability.
Less Post-Processing and Functional Components
Another advantage is that the high cutting quality significantly reduces the need for mechanical post-processing. As a result, the manufactured parts can often be used directly as functional components, for example in gear teeth or locking mechanisms.
Consequently, not only time but also production costs can be reduced in the long term.
Requirements for Presses in Fine Blanking
As already mentioned, compared to conventional cutting, fine blanking requires a special triple-acting press. This press is characterized in particular by exceptionally high ram guidance accuracy and a very rigid press frame.
This ensures that the entire cutting process takes place under consistently optimal conditions and delivers consistently precise results.
Tool Sets for Multi-Layer Components in Toolmaking
For example, when manufacturing shielding plates with an internal insulation layer, special tool sets are used in toolmaking for multi-layer components. This construction method not only allows for the processing of different materials but also ensures a precise bond between the individual layers.
Structure and Components of the Tool Sets
Such tool sets consist of several individual tools, each of which performs a clearly defined task. On the one hand, a blank cutting tool is used to precisely cut the outer layer blanks. On the other hand, a flanging tool is used to securely join the outer layers with the inner insulation layer.
In addition, a forming tool, such as a transfer tool, is frequently used to shape the components into their final form. Thus, all tools work together seamlessly to ensure a smooth manufacturing process.
Precision and Process Reliability in Manufacturing
All tools used have their own guide and positioning elements, ensuring precise further processing after each individual manufacturing step. This not only ensures dimensional accuracy but also achieves consistently high quality.
Consequently, even complex and multi-layer components are produced reliably, efficiently, and with high precision.
Cutting and Punching Tools in Toolmaking
When components do not require forming, the use of cutting and punching tools is often sufficient in toolmaking. This is because, in such cases, the component can be manufactured particularly efficiently using the so-called single-pass cutting process.
Full-cut tools for efficient manufacturing
When using full-cut tools, the component is fully manufactured in a single stroke. This not only enables short cycle times but also ensures cost-effective production.
Consequently, this process is particularly suitable for simple geometries and high-volume production, where speed and efficiency are paramount.
Division of the cutting process under high cutting force
However, if the required cutting force is too high, the cutting process can be adjusted accordingly. In this case, the process is divided into several stations, thereby reducing the load and increasing tool life.
This not only improves process reliability but also ensures consistently high component quality.
Fixture Design and Auxiliary and Prototype Tools in Toolmaking
When a project needs to be implemented quickly and cost-effectively, fixtures and auxiliary and prototype tools in toolmaking are the ideal solution. This is because, especially in early development phases or when dealing with short-notice requirements, these tools enable particularly flexible and efficient implementation.
Rapid Implementation and Flexible Manufacturing Processes
With the help of fixtures and auxiliary and prototype tools, both individual forming processes and cutting operations can be carried out quickly. This allows components to be not only manufactured quickly but also tested and optimized cost-effectively.
These solutions offer decisive advantages, particularly when testing new components or manufacturing processes, as adjustments can be made at short notice at any time.
Case Studies and References
In addition, our company presentation provides a comprehensive overview of projects we have already completed. There you will find numerous examples of successfully implemented fixtures as well as auxiliary and prototype tools.
This allows you to gain an impression not only of our experience but also of the diversity of our solutions in toolmaking.