Plastic meets microtechnology

In the recent Fakuma a small machine grasped my attention. This very compact injection machine is actually dedicated to microtechnology and realize parts with one or two components between 10 and 400 mg. Indeed that’s not an usual way to characterize parts in “classical microtechnology” were we do parts doing chips. Nevertheless this machine can produce true microtechnology parts in many different material (including CIM, PIM and MIM).

The formica Plast range comprises two machines, the 1K for smallest shot weights (10-200 mg) and the 2K for micro-injection with two components  (10-400 mg).

High precision for smallest shot weights is due to

• two-step plunger injection unit
• comfortable visualization
• precise control
• toggle clamp system
• standardized mould changing
• high dynamic servo-electric injection unit

The machines can be complemented with optional features like handling and quality insurance systems, video and clean room modules.

Micro injected parts? Can be found everywhere!
Micro moulded parts are produced in a safe and stable process. Technically demanding parts may be produced without manual or complex automated handling: multi-component systems are produced within the mould. formicaPlast 2K is of interest for many industrial branches including medicine, IT applications, telecommunications, automation, sensor and automobile technologies.
Applications include accelerating and pressure sensors, micro pumps for analytical purposes, components and component groups for hearing aids and acoustics, cogs and clutches or optical lenses.

For more information contact
DESMA TEC

Marten Beiersdorf – Sales Manager
Tel.: +49-4202-990 383
Fax.: +49-4202-990 210
m.beiersdorf@desma.de
www.desma-tec.de/en

Making Laser marking as easy as printing

Trumpf has become the first manufacturer of laser marking systems to connect a laser directly to SAP R/3 via a standard printer interface. TruMark marking lasers can now be hooked up and integrated with SAP systems just as easily as conventional inkjet and toner printers.

TruMark marking lasers can now be connected and integrated with SAP systems just as easily as standard inkjet and toner printers. Photo: Trumpf Group

The connection is established using the driver interface for printers included in the SAP® Printer Vendor program. The marking laser takes on the role of a printer, with the surface of the workpiece replacing the label or paper. This allows users to work from within the SAP system to apply company logos, model designations, codes and serial numbers to parts using a laser – without requiring any programming skills or additional software. The laser parameters required for a wide range of materials are included as part of the marking software package.

No additional software or hardware
Support for the SAP standard eliminates the need to invest in and maintain additional hardware and software, and direct marking of parts minimizes the use of consumables by applying the labeling information directly to the parts themselves. The surface markings are robust and durable and are designed to last for the duration of the product’s service life.
The decision to use a standard interface hugely simplifies the integration process. Trumpf’s new SAP driver is the perfect tool for customers with business models which use SAP to process orders immediately prior to dispatch, moving from the webshop to the labeling stage without switching between multiple media.

For further information about the company, please visit www.trumpf.com

Trumpf GmbH + Co. KG
Johann-Maus-Straße 2
71254 Ditzingen
Germany

Special tool from one piece

The watchmaking gears and wheels are strategic parts in the good functioning of a watch. Machining of these parts, carried out on an automatic lathe or on a dedicated gear cutting machine, often uses gear hobbing technology and requires special precision hobs. In these small sizes, each module and number of teeth involves the use of a dedicated hob.

Traditionally the realization of precision hobs is done by copying and inevitably requires numerous adjustment steps. It is not the case in the Jura company. Work basis is the CAD file of the part to be machined and the entire process remains digital until the realization of the hobs. Even more, this “digital integration from A to Z” allows the tools manufacturer to produce very small series (or single part) under very short deadlines and at very attractive prices.

A small number of suppliers
To succeed in such achievements, Louis Bélet SA can rely on a very sharp know-how in tooling, and dedicated software as well as 7 axes production machines (working with 5 axes simultaneously). Two new machines of this type were being installed while I visited early April. Mr. Maître explains the reasons for the implementation of these additional means of production: “There are only a few companies able to provide tools such as ours and parts manufacturers, active in watchmaking, medical or microtechnology, wish to secure their supplies while ensuring short deadlines”. In this regard, Louis Bélet SA is a key partner.

Further and further
Are you looking for customized tooling solutions or standard high-quality solutions? Both available under short deadlines? Louis Bélet SA is organized to deal with these two challenges.
The company will be present at the EPHJ show in Lausanne on its brand new booth… do not miss the opportunity.

Louis Bélet SA
Les Gasses 11 – CH-2943 Vendlincourt
Tel. +41 (0) 32 474 04 10 – Fax +41 (0) 32 474 45 42
info@beletsa.ch – www.beletsa.ch

Rotary Table Technology with Large Diameters in Best Form

Braunform is focusing on the current trend in tool and die technology for the K2010, concentrating primarily on tools for medical and multi-component technology. Braunform will be displaying a 32+32 rotary mould with a rotary table. Because of its slim design, the robust and fast rotary tables from the series 540 to the series 1400 (turning plate diameter 500mm to 1,360 mm) in accordance with EUROMAP, are going to be a highlight at the booth of the company out of Bahlingen.  As a pioneer of multi-component technology, Braunform is one of the few suppliers offering upper-class rotary tables with diameters between 900 mm and 1,400 mm.

„Thin“ constructional depth: 900mm rotary table from Braunform

Braunform has been engaged in this technology since 1990. Eckard Herb, Managing Director of Braunform has been observing this trend towards larger rotary tables for a while: „Increasingly complex geometries as well multi-cavity strategies demand increasingly larger rotary tables. They need to be compact as well as fast. What counts most in practice, however, is a robust and flexible rotary table.“ Braunform has an extensive program, including the „Titans“ among rotary tables offering products up to 1,400mm diameters (turning plate diameter 1,360 mm).

Advantages in Detail
Despite extreme dynamic forces, rotary tables from Bahlingen stand out because of their steadfast robustness. The root of this robustness is in the covered rotary plate which guarantees high lifetime cycles. The flexibility of the design offers the user a variety of advantages in daily operations and allows for fast and efficient solutions in multi-component technology. Connections on the front side provide for optimal water supply, guaranteeing efficient coolant circulation for short cycle times. Direct transmission to the tool is also an option which can be realized. Setting up moulds on rotary tables from Braunform is done without adaptors. This enables the user to change moulds quickly and efficiently. However, the newest generation of rotary tables from Braunform doesn’t only stand for efficient change-over times. The rotary tables are very flat. They stand out because of what their shallow depths allow for: shorter parting distances when opening the mould saves on cycle time and there is also more room for complex moulds. A variety of special options round up the program. Rotary tables of the series 540 to the series 1400 are offered as a Basic Line or Premium Line at a maximum tool weight ranging from 450 to 4,000 kg.

K2010: Braunform displays 900 mm multi-cavity rotary table with TPE/PS parts
Braunform is going to display a 900 mm rotary table out of its middle-sized assortment at the K2010. The 900 mm rotary table will be fitted with the mould half of a 32+32 multi-cavity mould (32+32 cavity SGW for Regular Head Guard). In the mould, a customer of Braunform will produce a 2 component TPE/PS-combined razor part with a part weight of 0,83 g/part. According to Braunform, this rotary table is suitable for machines with clamping forces of 2.500 to 2.750 kN with a turning rate of 1,5 sec during continuous operation.

Braunform at the K2010: Hall 1 Booth F30

Braunform GmbH
Kunststoff- und Pharmatechnik
Unter Gereuth 7 + 14
D-79353 Bahlingen
Germany
Phone +49 (0) 7663 / 9320-108
Fax +49 (0) 7663 / 9320-139
info@braunform.com
www.braunform.com

Custom-made – and quickly…

In the modern industrial world, we tend to talk of “custom-made and time-consuming” or “standard and available as of now”. Watchmakers G&F Châtelain have discovered an ideal alternative, combining flexibility and rapidity, for all its assembly-mounting, sandblasting, polishing and colouring-off  operations. We talked with Messrs Kamel Hadjadji, head of Methods, Patrick Oudot, mass production advisor at G&F Châtelain, and Vincent Dormoy, head of Sales for French-speaking Switzerland at Composites Busch in Porrentruy, the company behind this little miracle.

With several years of experience in sintering to his credit, the technician is an expert in all aspects of what is still a relatively young technology.

G&F Châtelain is not a watchmaking company in the proper sense of the term, as it produces no movements, dials or hands. The company manufactures all the other watch parts itself, which calls for numerous lines of business, all of which are extremely demanding in terms of know-how and quality. It owns a large number of machine tools of many different types, and its greatest assets are the skills of its operators.

Polyamide 12 saves the day
How did this company, which makes high-end watchmaking parts, even come to consider using parts made by sintering polyamide powder in its production process? Patrick Oudot:  “Originally, we contacted Composites Busch with the idea of producing small mounts for high-precision assemblies. However, during our talks at this first meeting, we discovered that we could do much more.” Vincent Dormoy adds: “That’s how we work; we listen to our customers and then together we find a solution that suits them. In this case, we saw that the supports had a lot of potential for manual machining operations. These are often carried out at the end of the production chain on valuable pieces, and so all innovations capable of guaranteeing the quality of these operations were welcome.”

Whatever the shape, however complex
All kinds of parts, from the simplest to the most complex, can be made with the technology used by Composites Busch. Kamel Hadjadji: “The parts that we produce are more and more complex – the shapes of the watches call for highly specific operations. For example, if we have to sandblast or bead-blast certain parts, we have to make a mask so that we only process the sections we want to process. Producing this kind of piece using conventional machining methods is very costly, or even impossible in some cases.”

The advantages of the solution offered by Composite Busch

• Total freedom as to the shape of the parts
• No danger of injury from the watches
• A pleasant material to handle
• Rapid process
• Parts can be adapted from batch to batch
• A cost-effective solution
• Ergonomic supports.

To be completed in a further issue of Eurotec.

Both companies will be present at EPHJ/EPMT in Lausanne:
Composites Busch SA – H 10, A20.
GF Châtelain H18, A5

Composites Busch SA
Chemin des Grandes-Vies 54 – CH-2900 Porrentruy
Tél. +41 32 465 70 30 – Fax +41 32 465 70 35
composites@busch.ch – www.compositesbusch.ch

G&F Châtelain SA
Allée Du Laser 18 – 2301, CH-La Chaux-De-Fonds
Tél. +41 32 924 55 55 – Fax +41 32 924 55 56

Increased capacity…

Since the takeover of André Gueissaz SA by Ruetschi technology in 2006, the manufacturer of plastic components has been moving towards the production of increasingly high-tech pieces. The R&D offices of the two companies merged in 2008 and the company’s rationalisation efforts entered a new phase in 2009, when work started on the construction of a new building.

Production and assembly side by side
This is a bold bet for the future by the manufacturer. Judge for yourself: the entire production facilities of André Gueissaz SA are to be moved to Yverdon into a brand-new building. The area given over to injection moulding machinery will be doubled in size and that for assembly substantially extended. Side by side on a single level, the entire production and assembly chain will enjoy more rational logistics.

Greater synergy
One trend in the production of high-technology parts for the medical or agri-food sectors is the combination of metal and plastics. The new premises of Gueissaz Plastic will communicate directly with the existing premises of the Ruetschi Group, resulting in substantially greater synergy between the two entities.

A clean room environment from start to finish
André Gueissaz will also be able to produce medical subassemblies entirely in a clean room environment, both injection moulding and assembly being conducted in these conditions. Wydler: “We were already able to work in a protective atmosphere, but with our new premises we’ll be entering a whole new dimension. With facilities like these and our newly certified processes, we’re paving the way for the future.”

To find out more about André Gueissaz, you can download the article published in Eurotec 365 here: http://eurotecmagazine.wordpress.com/articles/companies/

André Gueissaz SA
Grand-Rue 149
CH-1454 L´Auberson
Tél. +41 24 454 26 06
Fax +41 24 454 43 83
plastics@gueissaz.ch
www.gueissaz.ch

XXL laser sintering for large components

Laser sintering allows production on demand, saving time and reducing development costs. Hofmann Innovation AG presents the world’s largest selective laser sintering (SLS) system for plastics. With a usable volume of up to 1,500 mm x 500 mm x 500 mm (X|Y|Z axis), the “Hofmann Medea 1500” system now allows the sintering of large plastic components using a genuine single-step process.

Peter Mischke at the Hofmann Medea 1500′s control panel (Image: Hofman Innovation AG).

As a result, one-piece components with no adhesive joints or welded seams can be produced. For the first time ever, large components such as instrument panels and interior/exterior automotive parts can be manufactured using an inexpensive sintering process.

The significance of the SLS process
Selective laser sintering allows the manufacture of complex, three-dimensional functional prototypes or moulds. These are produced quickly and fully automatically on the basis of the component’s CAD data. The system developed by the Modellbau division uses this data (usually in STL format) to generate numerous layers or “slices”. As a result, the Hoffman Medea 1500 SLS can build up functional components in just a few hours. “A number of lasers can be used at the same time. This allows us to produce large prototypes more quickly,” said Peter Mischke, Head of the Rapid Prototyping Technologies department, part of the Hofmann Group’s Modellbau division.

A new level of quality
The new XXL-sized SLS system is highly versatile. It can produce thousands of different components at the same time – all in a single process. It also allows a greater variation in layer thickness compared to conventional SLS systems. Mischke explained: “Our new system enables us to produce a wider range of component sizes. At the same time, we can influence and actually configure the process much better than we could with conventional sintering systems.” By varying the layer thicknesses, greater precision or, alternatively, higher build-up speeds can be achieved. The revolutionary new system can also act as a development platform for alternative materials which up until now had been unsuitable for the SLS process. It therefore offers advantages as regards the size, volume or geometry of the components which can be produced and their overall quality.

Production on demand reduces development times and costs
SLS allows the integration of additional functions into a component so as to increase its value during the development phase. This in turn reduces production costs and the economic risks involved. A particular advantage of laser sintering from an industrial point of view is that it allows reliable production on demand.

Hofmann Modellbau as a service provider
When it comes to manufacturing sintered plastic prototypes, Hofmann offers its customers a comprehensive range of services. These include carrying out installation work or enhancing the components with vapour-deposited, painted or printed finishes. Hofmann can provide anything from large, functional parts to complete modules with the surface finish of a series component. As a result, customers can obtain laser sintered prototypes in sizes which were not previously available on the market.

Hofmann Innovation Group AG
An der Zeil 2
D-96215 Lichtenfels
Germany
Telephone +49 (0) 9571 – 76 67 00
Fax +49 (0) 9571 – 76 67 09
info@hig-ag.de
www.hig-ag.de

Two awards for Composites Busch S.A.

Composites Busch S.A., based in Porrentruy in Switzerland, has recently been awarded two prizes at the same time – company CEO Ahmet Muderris accepted the JEC Asia Award in the ‚Sports and Leisure‘ category in Singapore, and his company also picked up the 3rd price of the AVK Innovation Award in Stuttgart, Germany. Both awards relate to the recent development of a new resin system and its successful practical implementation. As part of this new development, Composites Busch worked closely with Huntsman Advanced Materials, which developed the resin system in accordance with the requirements set by Composites Busch.

.
Ceremony of AVK Innovation Award in Stuttgart: from left Dr. Gerd Esswein, Management AVK, André Müller, Huntsman Advanced Materials, Alain Lallemand, Sales Manager Composites Busch S.A., Ahmet Muderris, Managing Director Composites Busch S.A., Nicolas Bernet, Key Account Manager Composites Busch S.A., Jürgen H. Aurer, President AVK (Picture: Berendt, AVK)

High-End technology
Composites Busch is an innovative company with 32 employees specializing in the processing of composite materials. Alongside many products for the fields of medical technology, mechanical engineering, sports equipment and the watch industry, Busch is also the only company in the world to produce one-piece composite ice hockey sticks. Over the past few years, Composites Busch has also developed a further core competence, laser sintering technology, which is mainly used in prototyping and piece production.

Ice hockey and much more…
Composites Busch had already developed a one-piece ice hockey stick made from carbon more than 17 years ago. At the time, the company worked closely with Huntsman Advanced Materials, based in Basle, Switzerland. For the new generation of ice hockey sticks, Huntsman has developed ‚Araldite® Nano- Tech Composite‘, a material that is based on a patented nanotechnology concept. Using this new material, the stick‘s fracture resistance was significantly improved without negatively affecting other vital physical properties such as flexibility, temperature resistance and viscosity.

Nano-particles
The new material is based on the use of specific, dispersed organic nano-particles that display an outstanding toughening effect when incorporated into Araldite® resin. Before the new ‚Nano IV‘ ice hockey stick was put into production, it was subjected to extensive tests over two years. As part of this process, Composites Busch also worked together with both the Swiss Federal Institute of Technology Zurich (ETH Zürich) and the École Polytechnique Fédérale de Lausanne (EPFL). The final practical test was ultimately carried out at this year‘s World Ice Hockey Championships in Switzerland, for which various members of the Swiss national team and other national teams were equipped with Busch Nano IV sticks.

Innovation
Both these awards bear witness to the innovative path that Composites Busch has consistently followed over the past few years. In cooperation with expert partner Huntsman Advanced Materials, the company has successfully managed to develop and test a material and put it into production that substantially improves the end product. The new materials increases the stick‘s fracture resistance without requiring changes to the production process, tools or moulds.

Eurotec want to congratulate Composites Busch for these rewards! Do you want to know more about how Composites Busch can help the industry? You can (re)discover an excellent article published in Eurotec here.

Composites Busch S.A.
2900 Porrentruy
composites@busch.ch
www.compositesbusch.ch

Course: Polymer Microfabrication (1 day)

Besides silicon and the established MEMS/MOEMS technology polymer materials and the related microreplication technologies are becoming more and more important for the realization and commercial success of new microcomponents and microsystems. New nanostructuring methods like 2-photon-stereolithography and others are at the threshold of leaving the laboratory status and entering market.

October 13 and 14 (2x ½ day)
The course will cover the large variety of polymer materials, their fundamental chemical and physical properties and the derived microstructuring and replication possibilities. Direct and indirect micro- and nanostructuring methods like deep X-ray lithography, stereolithography, laser machining, nanoimprinting and others as well as the large family of replication methods like hot embossing and injection molding will be described in detail. Master and tooling fabrication methods like electroplating, electro discharge machining as well as mechanical and laser micromachining will be presented and discussed intensely.

Replicated polymer microstructure

.

A large number of application examples and case studies dealing with the accessible geometries, feasibility, and process characteristics will be used for the presentation of the polymer microfabrication importance. The course is given at two different dates. In autumn, in a one day presentation, the course concentrates on the basics to give an overview about the technologies. In spring, during the two day presentation, there is more space for specific details and discussion.

Target group
The course is designed for technical management, R&D engineers and production specialists who face challenges of material and product development, manufacturing technologies and high-volume applications as mid- and long-term R&D development.

Content

• Polymers: Fundamental chemical and physical properties
• Fabrication of molding tools: Fabrication principles and characteristics
• Rapid Prototyping in microsystem technology
• Polymer replication techniques: Reaction Molding, UV-Embossing, Hot Embossing and Injection Molding: Principles, equipment, applications and case studies
• From micro to nano: Nanoimprinting, soft lithography, nanostereolithography and other new developments.

Want to know more? It’s here.
You can register here.

20th Fakuma Breaks the 1000th Mark!

The Fakuma international trade fair for plastics processing is defying the economic slump with 992 currently registered exhibiting companies, once again with strong foreign participation amounting to 25%.

As of the beginning of June, project manager Annemarie Lipp once again announced very strong interested in the 20th Fakuma international trade fair for plastics processing: “992 companies from inside and outside of Germany have made firm bookings to date, which amounts to a very clear, forward-moving signal in these economically difficult times. In addition to this, with 758 domestic and 234 foreign exhibitors, we’re once again experiencing strong participation from Germany, as well as from all of the relevant industrial nations and newly industrialized countries. We’re confident that we’ll be able to break the 1000 mark before the summer holiday season begins, and can promise exhibitors and expert visitors alike a highly interesting 20th Fakuma with a clear-cut technological and business orientation.”

20th Fakuma – Highly practical, dazzling array of information
That this will indeed be the case is made apparent by the fact that private trade fair promoters P. E. Schall GmbH & Co. KG will orchestrate a truly dazzling information and communications array for the anniversary event which will take place at the ultramodern, further expanded Friedrichshafen Exhibition Centre on Lake Constance from the 13th through the 17th of October, 2009. For example, in addition to internationally unique exhibition offerings which cover all industry sectors in a comprehensive fashion, further opportunities for information and the exchange of ideas will also be provided in the form of the time tested exhibitor forum in hall B5, innovative theme parks covering microsystems technology as well as training and research in hall A6, and last but not least the well established plastics TV broadcasters who will also set up their studio in hall B5.

20th Fakuma – All plastics technologies on board
Now that recovery trends are beginning to take hold to a slight degree in various industry sectors, plastics processing may well be one of the first segments to profit from this situation. After all, tremendous effort towards lightweight construction, functions integration and efficient use of resources is leading in many cases to substitutes for metal components and sheet metal assemblies – through the use of modern and diverse, high performance plastics. These in turn frequently necessitate new, or at least more refined tooling systems and production setups, thus going full circle with regard to interest groups and target groups at the Fakuma international trade fair for plastics processing – especially in light of the fact that the field of plastics processing is only presented with all of its technologies, such as injection moulding, extrusion and thermoforming, at Fakuma, which offers all of these sectors an ideal presentation and business platform.

www.fakuma-messe.de

By the way, we recently published two interesting stories about “plastic”

• André Gueissaz SA: When plastic meets metal…
• Composites Busch: The products of the future are available now.