Imageflyer Kunststoff-Institut Luedenscheid

Innovations for the plastics industrycompetent | fast | practical

Distanceto Dortmund airport approximately 45 minutesto Düsseldorf airport approximately 70 minutesto Frankfurt airport approximately 100 minutes

Do you have any further questions?Please contact us:

General managers:Dipl.-Ing. Thomas Eulenstein

Dipl.-Ing. Stefan Schmidt

Kunststoff-Institut für die mittelständische Wirtschaft NRW GmbH (K.I.M.W.)Karolinenstraße 8 | 58507 LüdenscheidPhone: +49 (0) 23 51.10 64-191Fax: +49 (0) 23 51.10 64-190Web: www.kunststoff-institut.deMail: [email protected]

Exit 14, Lüdenscheid Mitte, follow the signs for „Zentrum“ or „EGC“. Do not take the tunnel („Rathaustunnel“) and instead keep to your right, and behind the railway station (on the right) take the 3rd street to the right, which is Karolinenstraße.

Exit 13, Lüdenscheid Nord, follow the road to Lüdenscheid, Heedfelder Straße, for approx. 2 km, after the church on the left-hand side, take a left turn into Lessingstraße and then turn left again into Karolinenstraße.

The walk from Lüdenscheid railway station takes approximately seven minutes.

By car (A 45)

���Products Innovations ���

Performance

Innovations

���

1 3iTech®

Inductive heating of injection moulds, an efficient temperature control alternative for optimizing the surface quality of injection moulded parts.

2 Backfilling of metalsManufacturing of high-quality metal surfaces, combinati-ons of metal optics, cool touch effect and the functionali-ty of plastics (e.g. car interior mouldings).

3 Laser CUSING®

Layered design of the mould inserts by means of the laser fusing of metal powder.

4 Seal-Fit® A special polyamide for the manufacturing of media-tight metal/plastic composites by using injection moulding technology.

5 MurSeal® (A4200)Flexible sealing element for flash and damage-free en-capsulation, e.g. of lacquered inserts for the processing of thermoplastics.

The Kunststoff-Institut Lüdenscheid� provides support in the selection, development, and

optimization of products, tools, and processes in all areas of plastics technology

��is focused on increasing the quality and economic efficiency in the plastics industry

��was founded in 1988 as an “extended workbench” and is thus one of the most experienced service

providers in this field of expertise��is a private sector service provider��currently employs a staff of approximately 45 people��generates an annual turnover of more than four million euros

54

1

2 3

Data & Facts Performance

Products

Data & Facts

��� ���

The Kunststoff-Institut has developed numerous products of their own, which offer users valuable information and support for their production process.

��Guide – to defects on thermoplastic and thermoset pressed and injection moulded parts and to the setting of injection moulding machines

��MurSeal® (A4200) – flexible sealing element for injec-tion moulds

��WinCool – computer programme for the calculation of cycle times for thermoplastic injection moulded parts

��Visual SPC – computer programme for the calculation and analysis of processes

��Crack Knacker® – test medium for the visualisation of defects on plastic parts; stress crack test

��Structure plates – DIN A5 sample plates with diffe-rent VDI structure classes

��Several test specimens

Telephone: +49 (0) 23 51.10 64-119

Elke Dormann |

The Kunststoff-Institut combines tomorrow’s scientific know-how with today’s production capabilities. Our focus is placed on increasing quality and economic efficiency – especially for injection moulded parts that are made of thermoplastic and thermoset materials.

The Kunststoff-Institut Lüdenscheid attaches great importance to the following issues:� Maximum competence is guaranteed by our qualified

and extensively experienced employees as well as our strict quality management systems

� Fast and flexible order processing

� Strictly keeping in mind the matter of practical appli-cation and, therefore, the application-oriented support of our customers

Our enterprise as a whole is DIN EN ISO 9001 certified; the laboratory is accredited to DIN EN ISO/IEC 17025:2000.

���Moulded part and mould optimization ���Education and training

Material testing

Education and training

Telephone: +49 (0) 23 51.10 64-115

Torsten Urban | Oliver Rattay | Eva Hitzegrad | Sandra Wagner |

The events that are organised by the training centre of the Kunststoff-Institut are characterised by practical re-levance. The participants can expect new and state-of-the-art technical topics due to the numerous research projects that are carried out by the institute.

� Fully air-conditioned lecture rooms and specifically equipped pilot plant

� One or two day seminars, crash courses, workshops, and one-week courses as well as lectures all allow for individual scheduling

� Group training in the pilot plant, laboratory, and in the application centre for surface technology (AOT) will further intensify the practical relevance

� Company-specific training in the institute or on-site in Germany or abroad with a detailed focus on the speci-fic individual company requirements

� Written and/or oral exams in order to document the efficiency

� Symposia on interesting technical topics as an ideal platform for discussions among experts

Telephone: +49 (0) 23 51.10 64-119

Jens Hündorf | Horst Wilhelm | Thorsten Helbig |Erich Wunderwald | Klaus Schulte | Elke Dormann |The modern laboratory, which is DIN EN ISO/IEC17025

accredited, is equipped with high-quality test instruments for analysing materials and parts.� Material and incoming goods inspections� Viscosity number, melt volume rate (MVR)/melt flow

rate (MFR) � Mechanical testing: tensile test, flexural test and impact test� Thermal properties: melting point, Vicat softening

point, HDT measurements, etc.� Chemical resistance/heat ageing� Test specimen production/standard test specimens� Testing as per automotive standards (DBL, GME, TL, etc.)� Xenon arc light ageing test (VDA 75202, etc.) and solar

simulation (DIN 75220)

� Climatic tests (PV 1200, BMW PR303.4)� Emission testing (VW 50180, Fogging, odours, etc.)� Flammability testing (FMVSS 302, DIN 75200, UL 94)� Material requirements (DBL 5404, TL 527, etc.)� Surface testing according to specifications: e.g. TL

226, DBL 7384, cream and scratch resistance� Proficiency tests in the field of plastics testing and ana-

lysis (www.proficiency-test.info)

A free copy of our extensive seminar programme, with all the dates and topics, is available upon request. We will be pleased to develop a training concept that is customised for your company.

���Material testing ���Failure analysis

Moulded part and mould optimization

Failure analysis & material identification

Telephone: +49 (0) 23 51.10 64-119

Andreas Balster | Andrea Saß | Peter Bamfaste | Meike Kling | Margarita Stoppel | Hendrik Koerdt | Elke Dormann |

The optimization of moulded parts and moulds is beco-ming more important in the plastics industry, since the demands on the production, especially in view of global competition, are also increasing.

The Kunststoff-Institut Lüdenscheid provides support in the following tasks:� Optimization of the geometry of the moulded part in

terms of the positioning of weld lines, venting pro-blems, warpage problems, and strengths

� Flow and thermal optimization of the mould in order to achieve the shortest cycle times (MOLDFLOW/Moldex 3D analyses)

� Mechanical component analyses (structural mechanics).� Special procedures (e.g. core shift, sandwich technolo-

gy and encapsulation of metal inserts)� Production of mould inserts with form-fitting tempera-

ture control by means of Laser CUSING® (rapid tooling)

The failure of moulded plastic parts or their surface coa-tings constitutes an incalculable risk for their producer - financially as well as in terms of the damage caused to the company’s reputation.

The Kunststoff-Institut provides support in finding the root cause for a failure and presents options for preven-ting them in the future. The available resources include the equipment in our own accredited laboratory as well as a network of competent and experienced partners to cover the entire range of plastics and surface analytics. Our customers will receive a meaningful, precise and in-telligible test report and, if desired, will be accompanied in eliminating the root cause of the failure and in the opti-

Telephone: +49 (0) 23 51.10 64-145

Markus Schnietz | Frank Ohm |

mization of the concerned process and/or component.Contact us as a neutral evaluation institution in the case of failures or disputes; we always have the time for a non-committal counselling interview. Discretion can be taken for granted, as this is a central and indispensable part of our service.

Materials Engineering/New Materials ���Quality management

Surface technology

Quality management

Telephone: +49 (0) 23 51.10 64-191

Torsten Urban |

���

The Kunststoff-Institut provides support in the selection, application, and evaluation of the optimum surface treat-ment techniques for moulded parts as well as moulds.

Surface technology for moulded parts� Selection of surface and decorative treatments, inclu-

ding the introduction of new decoration technologies� Process developments and optimizations as well as

process combinations

Surface technology for the moulds/components� Compilation of mould specifications� Application-oriented selection of surface and coating

technologies� Lubricant-free production and generation of design

surfaces by means of surface and layer technologies

In the plastics industry, the demands on quality and envi-ronmental management are constantly increasing due to the legal requirements and/or customer specifications.

The Kunststoff-Institut provides expertise in the following areas:� Setup, optimization, and auditing of QM/EM systems� Execution of process analyses� Compilation of process parameters� Benchmarking processes� Supplier evaluation including make-or-buy decisions� Support for the execution/introduction of sampling

procedures (PPAP/VDA), advanced product quality planning (APQP), as well as quality techniques (FMEA, SPC, CIP and Six Sigma)

Telephone: +49 (0) 23 51.10 64-130

Jörg Günther | Udo Hinzpeter | Ralf Zahradnik | Detlev Berndt | Angelo Librizzi | Dominik Malecha |

Surface analysis technology� Extensive analysis technology such as colour and gloss

measurements, contactless roughness and topography measurements, surface energy, scratch and abrasion resistance, and measurement of the coating thickness (q.v. Laboratory)

� Support in the compilation of analysis specifications

AOT ������Surface technology

Materials Engineering/New Materials

AOT (Application Centre Surface Technology)

Telephone: +49 (0) 23 51.10 64-130

Jörg Günther | Detlev Berndt | Ralf Zahradnik |

The development and use of intelligent materials are among the key technologies for securing and developing production locations in Germany and moreover becoming an important part of the value added chain. In general, there is a need for more interaction between material de-velopers and companies. Only those who know (or recog-nise) the possibilities of the market and the raw material development are truly capable of positioning innovative and market-driven products. However, this requires medi-ation between research on one side and entrepreneurship on the other to possibly initiate own innovative material developments.The Kunststoff-Institut provides support in the follo-wing areas:� Definition of the requirement profiles� Material selection� Reduction of material variety/cost reduction� Evaluation, development and validation of functional

materials for industry-specific solutions� Material analyses

Telephone: +49 (0) 23 51.10 64-160

Michael Tesch | Julia Schmitz |

� Prototypes, initial samples and small batch production� Layer and parameter optimization� Development, testing and qualification of new systems and process combinations� Failure analysis and prevention

Technical Equipment� Robotic paint system (hydro, solvent, and UV systems)� Pilot plant electroplating� IMD production unit and a thermoforming machine� Water transfer printing and digital printing� Laser marking and engraving� Pad printing and hot stamping� Corona, low pressure and atmospheric plasma� Microblasting and component cleaning

���Process engineering

Process engineering

Process development

Telephone: +49 (0) 23 51.10 64-170

Marius Fedler | Udo Hinzpeter | Michael Talhof | Andreas Plöhn | Timo Schulz | Stefan Hins | Sebastian Theis |

With its outstanding technical equipment and extensive experience, the Kunststoff-Institut can support its custo-mers in the field of process engineering.� Mould proving on eight injection moulding machines

(220-4.000 KN)� Multi-component injection moulding� Injection stamping� Clean room technology� Film insert moulding� Encapsulation of inserts� Small-scale production� On-site process engineering support� Production of test specimens� Potting of sensitive components� Employee qualification with an emphasis placed on

mould and process optimization

With their own development of processes, the Kunststoff-Institut contributes to the following issues, depending on the application:

� Shortening of process chains� Reduction of costs per piece� Increase of quality standards� Decrease of reject rates

The Kunststoff-Institut provides support in the following areas:� Introduction of new production processes as far as the

series readiness� Development and modification of injection moulds by

means of new technologies� Process automation� Implementation of assembly processes into an injec-

tion mould

Telephone: +49 (0) 23 51.10 64-197

Michael Talhof | Andreas Plöhn | Daniel Greitsch |

� Guidance throughout the process from the product idea to large volume production

� Application-oriented process selection

Process development ���

���Process engineering

Process engineering

Process development

Telephone: +49 (0) 23 51.10 64-170

Marius Fedler | Udo Hinzpeter | Michael Talhof | Andreas Plöhn | Timo Schulz | Stefan Hins | Sebastian Theis |

With its outstanding technical equipment and extensive experience, the Kunststoff-Institut can support its custo-mers in the field of process engineering.� Mould proving on eight injection moulding machines

(220-4.000 KN)� Multi-component injection moulding� Injection stamping� Clean room technology� Film insert moulding� Encapsulation of inserts� Small-scale production� On-site process engineering support� Production of test specimens� Potting of sensitive components� Employee qualification with an emphasis placed on

mould and process optimization

With their own development of processes, the Kunststoff-Institut contributes to the following issues, depending on the application:

� Shortening of process chains� Reduction of costs per piece� Increase of quality standards� Decrease of reject rates

The Kunststoff-Institut provides support in the following areas:� Introduction of new production processes as far as the

series readiness� Development and modification of injection moulds by

means of new technologies� Process automation� Implementation of assembly processes into an injec-

tion mould

Telephone: +49 (0) 23 51.10 64-197

Michael Talhof | Andreas Plöhn | Daniel Greitsch |

� Guidance throughout the process from the product idea to large volume production

� Application-oriented process selection

Process development ���

AOT ������Surface technology

Materials Engineering/New Materials

AOT (Application Centre Surface Technology)

Telephone: +49 (0) 23 51.10 64-130

Jörg Günther | Detlev Berndt | Ralf Zahradnik |

The development and use of intelligent materials are among the key technologies for securing and developing production locations in Germany and moreover becoming an important part of the value added chain. In general, there is a need for more interaction between material de-velopers and companies. Only those who know (or recog-nise) the possibilities of the market and the raw material development are truly capable of positioning innovative and market-driven products. However, this requires medi-ation between research on one side and entrepreneurship on the other to possibly initiate own innovative material developments.The Kunststoff-Institut provides support in the follo-wing areas:� Definition of the requirement profiles� Material selection� Reduction of material variety/cost reduction� Evaluation, development and validation of functional

materials for industry-specific solutions� Material analyses

Telephone: +49 (0) 23 51.10 64-160

Michael Tesch | Julia Schmitz |

� Prototypes, initial samples and small batch production� Layer and parameter optimization� Development, testing and qualification of new systems and process combinations� Failure analysis and prevention

Technical Equipment� Robotic paint system (hydro, solvent, and UV systems)� Pilot plant electroplating� IMD production unit and a thermoforming machine� Water transfer printing and digital printing� Laser marking and engraving� Pad printing and hot stamping� Corona, low pressure and atmospheric plasma� Microblasting and component cleaning

Materials Engineering/New Materials ���Quality management

Surface technology

Quality management

Telephone: +49 (0) 23 51.10 64-191

Torsten Urban |

���

The Kunststoff-Institut provides support in the selection, application, and evaluation of the optimum surface treat-ment techniques for moulded parts as well as moulds.

Surface technology for moulded parts� Selection of surface and decorative treatments, inclu-

ding the introduction of new decoration technologies� Process developments and optimizations as well as

process combinations

Surface technology for the moulds/components� Compilation of mould specifications� Application-oriented selection of surface and coating

technologies� Lubricant-free production and generation of design

surfaces by means of surface and layer technologies

In the plastics industry, the demands on quality and envi-ronmental management are constantly increasing due to the legal requirements and/or customer specifications.

The Kunststoff-Institut provides expertise in the following areas:� Setup, optimization, and auditing of QM/EM systems� Execution of process analyses� Compilation of process parameters� Benchmarking processes� Supplier evaluation including make-or-buy decisions� Support for the execution/introduction of sampling

procedures (PPAP/VDA), advanced product quality planning (APQP), as well as quality techniques (FMEA, SPC, CIP and Six Sigma)

Telephone: +49 (0) 23 51.10 64-130

Jörg Günther | Udo Hinzpeter | Ralf Zahradnik | Detlev Berndt | Angelo Librizzi | Dominik Malecha |

Surface analysis technology� Extensive analysis technology such as colour and gloss

measurements, contactless roughness and topography measurements, surface energy, scratch and abrasion resistance, and measurement of the coating thickness (q.v. Laboratory)

� Support in the compilation of analysis specifications

���Material testing ���Failure analysis

Moulded part and mould optimization

Failure analysis & material identification

Telephone: +49 (0) 23 51.10 64-119

Andreas Balster | Andrea Saß | Peter Bamfaste | Meike Kling | Margarita Stoppel | Hendrik Koerdt | Elke Dormann |

The optimization of moulded parts and moulds is beco-ming more important in the plastics industry, since the demands on the production, especially in view of global competition, are also increasing.

The Kunststoff-Institut Lüdenscheid provides support in the following tasks:� Optimization of the geometry of the moulded part in

terms of the positioning of weld lines, venting pro-blems, warpage problems, and strengths

� Flow and thermal optimization of the mould in order to achieve the shortest cycle times (MOLDFLOW/Moldex 3D analyses)

� Mechanical component analyses (structural mechanics).� Special procedures (e.g. core shift, sandwich technolo-

gy and encapsulation of metal inserts)� Production of mould inserts with form-fitting tempera-

ture control by means of Laser CUSING® (rapid tooling)

The failure of moulded plastic parts or their surface coa-tings constitutes an incalculable risk for their producer - financially as well as in terms of the damage caused to the company’s reputation.

The Kunststoff-Institut provides support in finding the root cause for a failure and presents options for preven-ting them in the future. The available resources include the equipment in our own accredited laboratory as well as a network of competent and experienced partners to cover the entire range of plastics and surface analytics. Our customers will receive a meaningful, precise and in-telligible test report and, if desired, will be accompanied in eliminating the root cause of the failure and in the opti-

Telephone: +49 (0) 23 51.10 64-145

Markus Schnietz | Frank Ohm |

mization of the concerned process and/or component.Contact us as a neutral evaluation institution in the case of failures or disputes; we always have the time for a non-committal counselling interview. Discretion can be taken for granted, as this is a central and indispensable part of our service.

���Moulded part and mould optimization ���Education and training

Material testing

Education and training

Telephone: +49 (0) 23 51.10 64-115

Torsten Urban | Oliver Rattay | Eva Hitzegrad | Sandra Wagner |

The events that are organised by the training centre of the Kunststoff-Institut are characterised by practical re-levance. The participants can expect new and state-of-the-art technical topics due to the numerous research projects that are carried out by the institute.

� Fully air-conditioned lecture rooms and specifically equipped pilot plant

� One or two day seminars, crash courses, workshops, and one-week courses as well as lectures all allow for individual scheduling

� Group training in the pilot plant, laboratory, and in the application centre for surface technology (AOT) will further intensify the practical relevance

� Company-specific training in the institute or on-site in Germany or abroad with a detailed focus on the speci-fic individual company requirements

� Written and/or oral exams in order to document the efficiency

� Symposia on interesting technical topics as an ideal platform for discussions among experts

Telephone: +49 (0) 23 51.10 64-119

Jens Hündorf | Horst Wilhelm | Thorsten Helbig |Erich Wunderwald | Klaus Schulte | Elke Dormann |The modern laboratory, which is DIN EN ISO/IEC17025

accredited, is equipped with high-quality test instruments for analysing materials and parts.� Material and incoming goods inspections� Viscosity number, melt volume rate (MVR)/melt flow

rate (MFR) � Mechanical testing: tensile test, flexural test and impact test� Thermal properties: melting point, Vicat softening

point, HDT measurements, etc.� Chemical resistance/heat ageing� Test specimen production/standard test specimens� Testing as per automotive standards (DBL, GME, TL, etc.)� Xenon arc light ageing test (VDA 75202, etc.) and solar

simulation (DIN 75220)

� Climatic tests (PV 1200, BMW PR303.4)� Emission testing (VW 50180, Fogging, odours, etc.)� Flammability testing (FMVSS 302, DIN 75200, UL 94)� Material requirements (DBL 5404, TL 527, etc.)� Surface testing according to specifications: e.g. TL

226, DBL 7384, cream and scratch resistance� Proficiency tests in the field of plastics testing and ana-

lysis (www.proficiency-test.info)

A free copy of our extensive seminar programme, with all the dates and topics, is available upon request. We will be pleased to develop a training concept that is customised for your company.

Data & Facts Performance

Products

Data & Facts

��� ���

The Kunststoff-Institut has developed numerous products of their own, which offer users valuable information and support for their production process.

��Guide – to defects on thermoplastic and thermoset pressed and injection moulded parts and to the setting of injection moulding machines

��MurSeal® (A4200) – flexible sealing element for injec-tion moulds

��WinCool – computer programme for the calculation of cycle times for thermoplastic injection moulded parts

��Visual SPC – computer programme for the calculation and analysis of processes

��Crack Knacker® – test medium for the visualisation of defects on plastic parts; stress crack test

��Structure plates – DIN A5 sample plates with diffe-rent VDI structure classes

��Several test specimens

Telephone: +49 (0) 23 51.10 64-119

Elke Dormann |

The Kunststoff-Institut combines tomorrow’s scientific know-how with today’s production capabilities. Our focus is placed on increasing quality and economic efficiency – especially for injection moulded parts that are made of thermoplastic and thermoset materials.

The Kunststoff-Institut Lüdenscheid attaches great importance to the following issues:� Maximum competence is guaranteed by our qualified

and extensively experienced employees as well as our strict quality management systems

� Fast and flexible order processing

� Strictly keeping in mind the matter of practical appli-cation and, therefore, the application-oriented support of our customers

Our enterprise as a whole is DIN EN ISO 9001 certified; the laboratory is accredited to DIN EN ISO/IEC 17025:2000.

���Products Innovations ���

Performance

Innovations

���

1 3iTech®

Inductive heating of injection moulds, an efficient temperature control alternative for optimizing the surface quality of injection moulded parts.

2 Backfilling of metalsManufacturing of high-quality metal surfaces, combinati-ons of metal optics, cool touch effect and the functionali-ty of plastics (e.g. car interior mouldings).

3 Laser CUSING®

Layered design of the mould inserts by means of the laser fusing of metal powder.

4 Seal-Fit® A special polyamide for the manufacturing of media-tight metal/plastic composites by using injection moulding technology.

5 MurSeal® (A4200)Flexible sealing element for flash and damage-free en-capsulation, e.g. of lacquered inserts for the processing of thermoplastics.

The Kunststoff-Institut Lüdenscheid� provides support in the selection, development, and

optimization of products, tools, and processes in all areas of plastics technology

��is focused on increasing the quality and economic efficiency in the plastics industry

��was founded in 1988 as an “extended workbench” and is thus one of the most experienced service

providers in this field of expertise��is a private sector service provider��currently employs a staff of approximately 45 people��generates an annual turnover of more than four million euros

54

1

2 3

Innovations for the plastics industrycompetent | fast | practical

Distanceto Dortmund airport approximately 45 minutesto Düsseldorf airport approximately 70 minutesto Frankfurt airport approximately 100 minutes

Do you have any further questions?Please contact us:

General managers:Dipl.-Ing. Thomas Eulenstein

Dipl.-Ing. Stefan Schmidt

Kunststoff-Institut für die mittelständische Wirtschaft NRW GmbH (K.I.M.W.)Karolinenstraße 8 | 58507 LüdenscheidPhone: +49 (0) 23 51.10 64-191Fax: +49 (0) 23 51.10 64-190Web: www.kunststoff-institut.deMail: [email protected]

Exit 14, Lüdenscheid Mitte, follow the signs for „Zentrum“ or „EGC“. Do not take the tunnel („Rathaustunnel“) and instead keep to your right, and behind the railway station (on the right) take the 3rd street to the right, which is Karolinenstraße.

Exit 13, Lüdenscheid Nord, follow the road to Lüdenscheid, Heedfelder Straße, for approx. 2 km, after the church on the left-hand side, take a left turn into Lessingstraße and then turn left again into Karolinenstraße.

The walk from Lüdenscheid railway station takes approximately seven minutes.

By car (A 45)