Product development

Successful product development requires clearly structured and well-coordinated processes. We support product ideas from the initial technical concept and CAD design through to prototype development and production-ready part design.
Our focus is not only on product geometry, but also on manufacturability, mold feasibility and cost-efficient series production.

We have extensive experience in industries such as medical technology, automotive engineering, household appliances, electrical engineering, water-bearing fittings and compressed air technology

Piercing Needles Made from Technical Ceramics

These molded parts are a good example of demanding product development with high requirements in terms of function, material and manufacturing. The component opens the coffee capsule directly before the brewing process and must operate reliably throughout the entire service life of the coffee machine.

Challenges solved:

• Sharp tips and edges without complex hard machining
• Realization of thin ribs and delicate geometries
• Integration of cross holes and threads
• Design suitable for series production
• Material-specific design for technical ceramics

Grinding Discs Made from Technical

The use of grinding discs in fully automatic coffee machines is another demanding example of function-oriented product design. The molded parts must provide precise grinding over a long service life and ensure a consistent particle size distribution even after many grinding cycles.

Design services in the product development process include:

• Design of the grinding geometry for a constant coffee quantity and uniform particle size distribution
• Material-specific design for technical ceramics
• Integration of a bayonet lock for easy assembly with the plastic mating component
• Design for manufacturing without subsequent finishing operations
• Construction taking chemical resistance and thermal loads into account

This example shows how design expertise, material knowledge and manufacturing-oriented engineering are combined to create a durable component suitable for series production.

Minimally Invasive Surgical System

The product design of all molded parts for a technical assembly requires a high level of precision, as each individual component must be functionally, dimensionally and manufacturably coordinated with the other components.
In this project, all plastic molded parts required for the assembly were designed according to the specification sheet and supported through to series production readiness.

Technical challenges during development:

• Dimensional coordination of the individual components
• Ensuring assembly capability within the complete system
• Consideration of tight functional and fitting tolerances
• Material-specific design for PA66/PA6 GF50
• Design for high stiffness and dimensional stability, including FEM analysis
• Consideration of shrinkage and warpage in glass-fiber-reinforced plastic
• Injection-molding-oriented part design
• Design and layout of all molds
• Design of the corresponding injection molds
• Support of the molds during manufacturing
• Acceptance of the plastic parts with measurement reports
• Optimization up to series-ready part qualityt

This example demonstrates comprehensive expertise from product design and mold layout through to quality-assured release for series production.