competent | fast | practical

Innovations for the plastics industry

Performance
The Kunststoff-Institut Ldenscheid 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 efciency in the plastics industry was founded in 1988 as an extended workbench and is thus one of the most experienced service providers in this eld 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

Data & Facts

The Kunststoff-Institut combines tomorrows scientic know-how with todays production capabilities. Our focus is placed on increasing quality and economic efciency especially for injection moulded parts that are made of thermoplastic and thermoset materials. The Kunststoff-Institut Ldenscheid attaches great importance to the following issues: Maximum competence is guaranteed by our qualied and extensively experienced employees as well as our strict quality management systems Fast and exible order processing Strictly keeping in mind the matter of practical application and, therefore, the application-oriented support of our customers Our enterprise as a whole is DIN EN ISO 9001 certied; the laboratory is accredited to DIN EN ISO/IEC 17025:2000.

Performance

Data & Facts

Material testing
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 ow rate (MFR) Mechanical testing: tensile test, exural 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 specications: e.g. TL 226, DBL 7384, cream and scratch resistance Prociency tests in the eld of plastics testing and analysis (www.prociency-test.info) Jens Hndorf | Horst Wilhelm | Thorsten Helbig | Erich Wunderwald | Klaus Schulte | Elke Dormann | Telephone: +49 (0) 23 51.10 64-119

Failure analysis & material identification

The failure of moulded plastic parts or their surface coatings constitutes an incalculable risk for their producer - nancially as well as in terms of the damage caused to the companys reputation. The Kunststoff-Institut provides support in nding the root cause for a failure and presents options for preventing 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 intelligible test report and, if desired, will be accompanied in eliminating the root cause of the failure and in the optimization 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. Andreas Balster | Andrea Sa | Peter Bamfaste | Meike Kling | Margarita Stoppel | Hendrik Koerdt | Elke Dormann | Telephone: +49 (0) 23 51.10 64-119

Material testing

Failure analysis

Surface technology
The Kunststoff-Institut provides support in the selection, application, and evaluation of the optimum surface treatment techniques for moulded parts as well as moulds. Surface technology for moulded parts Selection of surface and decorative treatments, including the introduction of new decoration technologies Process developments and optimizations as well as process combinations Surface technology for the moulds/components Compilation of mould specications Application-oriented selection of surface and coating technologies Lubricant-free production and generation of design surfaces by means of surface and layer technologies 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 specications Jrg Gnther | Udo Hinzpeter | Ralf Zahradnik | Detlev Berndt | Angelo Librizzi | Dominik Malecha | Telephone: +49 (0) 23 51.10 64-130

AOT (Application Centre Surface Technology)

Jrg Gnther | Detlev Berndt | Ralf Zahradnik | Prototypes, initial samples and small batch production Layer and parameter optimization Development, testing and qualication 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 Telephone: +49 (0) 23 51.10 64-130

Surface technology

AOT

Process engineering
Michael Talhof | Andreas Plhn | Daniel Greitsch | With its outstanding technical equipment and extensive experience, the Kunststoff-Institut can support its customers in the eld 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 qualication with an emphasis placed on mould and process optimization Telephone: +49 (0) 23 51.10 64-197

Process development
With their own development of processes, the KunststoffInstitut 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 modication of injection moulds by means of new technologies Process automation Implementation of assembly processes into an injection mould Guidance throughout the process from the product idea to large volume production Application-oriented process selection Marius Fedler | Udo Hinzpeter | Michael Talhof | Andreas Plhn | Timo Schulz | Stefan Hins | Sebastian Theis | Telephone: +49 (0) 23 51.10 64-170

Process engineering

Process development

Materials Engineering/New Materials

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 developers and companies. Only those who know (or recognise) the possibilities of the market and the raw material development are truly capable of positioning innovative and market-driven products. However, this requires mediation between research on one side and entrepreneurship on the other to possibly initiate own innovative material developments. The Kunststoff-Institut provides support in the following areas: Denition of the requirement proles Material selection Reduction of material variety/cost reduction Evaluation, development and validation of functional materials for industry-specic solutions Material analyses Michael Tesch | Julia Schmitz | Telephone: +49 (0) 23 51.10 64-160

Quality management
Torsten Urban | In the plastics industry, the demands on quality and environmental management are constantly increasing due to the legal requirements and/or customer specications. 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 64-191

Materials Engineering/New Materials

Quality management

Moulded part and mould optimization

Markus Schnietz | Frank Ohm | Telephone: +49 (0) 23 51.10 64-145 The optimization of moulded parts and moulds is becoming more important in the plastics industry, since the demands on the production, especially in view of global competition, are also increasing. The Kunststoff-Institut Ldenscheid provides support in the following tasks: Optimization of the geometry of the moulded part in terms of the positioning of weld lines, venting problems, 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 technology and encapsulation of metal inserts) Production of mould inserts with form-tting temperature control by means of Laser CUSING (rapid tooling)

Education and training

The events that are organised by the training centre of the Kunststoff-Institut are characterised by practical relevance. The participants can expect new and state-ofthe-art technical topics due to the numerous research projects that are carried out by the institute. Fully air-conditioned lecture rooms and specically 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-specic training in the institute or on-site in Germany or abroad with a detailed focus on the specic individual company requirements Written and/or oral exams in order to document the efciency Symposia on interesting technical topics as an ideal platform for discussions among experts Torsten Urban | Oliver Rattay | Eva Hitzegrad | Sandra Wagner | Telephone: +49 (0) 23 51.10 64-115 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.

Moulded part and mould optimization

Education and training

Products
Elke Dormann | Telephone: +49 (0) 23 51.10 64-119 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) exible sealing element for injection 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 different VDI structure classes Several test specimens

Innovations
1 3iTech Inductive heating of injection moulds, an efcient temperature control alternative for optimizing the surface quality of injection moulded parts. 2 Backlling of metals Manufacturing of high-quality metal surfaces, combinations of metal optics, cool touch effect and the functionality 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 ash and damage-free encapsulation, e.g. of lacquered inserts for the processing of thermoplastics. 4 5 2 3 1

Products

Innovations

Do you have any further questions?

Please contact us: General managers: Dipl.-Ing. Thomas Eulenstein Dipl.-Ing. Stefan Schmidt

Kunststoff-Institut fr die mittelstndische Wirtschaft NRW GmbH (K.I.M.W.) Karolinenstrae 8 | 58507 Ldenscheid Phone: +49 (0) 23 51.10 64-191 Fax: +49 (0) 23 51.10 64-190 Web: www.kunststoff-institut.de Mail: mail@kunststoff-institut.de

By car (A 45)
Exit 14, Ldenscheid 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 Karolinenstrae. Exit 13, Ldenscheid Nord, follow the road to Ldenscheid, Heedfelder Strae, for approx. 2 km, after the church on the left-hand side, take a left turn into Lessingstrae and then turn left again into Karolinenstrae. The walk from Ldenscheid railway station takes approximately seven minutes.

Distance to Dortmund airport approximately 45 minutes to Dsseldorf airport approximately 70 minutes to Frankfurt airport approximately 100 minutes