Compression Molding

We manufacture a wide variety of cases and molded parts on compression molding machines. Our compression molding machines range from smaller to large formats and have a strong press force to compress plastics and fleece. During the compression molding process, we heat the material in a contact heater and then form it in a mold. For this we need specific molds which can be made cost-effective compared to other production processes. By separating the heating and molding/cooling station, we can reach very short cycle times. This synchronization between heating and press modules enables us to optimize throughput times. This means that a serial production can be done very efficiently.

  • Flexible Design through Segmented Pressing

    Through targeted heating and the corresponding tools, it is possible to press the non-wovens completely or only partially. Therefore it is possible to integrate acoustically effective cushions / upholstery into an otherwise rigid component.

  • Creative Decors through Lamination

    Non-wovens can be laminated during the forming process with a foil, fleece or with textile decor material (one-shot process). This results in a greater flexibility of surfaces decorations and colors.
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Technical Details

TYPE

Compression Molding

SIZE

Up to 2000 x 1000 mm (several small formats)

Materials we process

We mainly process fleece materials using compression molding. There is a wide variety here, ranging from bio-based to biodegradable and recyclable.

More about fleece

How compression molding works

Fine tuning for an exact result

In the molding process, we can calibrate the pressing force, heating time and press length with a vast variety of options. It allows the parts to have flexible 3D shapes and to achieve a desired strength of the component. Haptics and material properties can additionally be influenced.

  • Cutting

    Depending on the geometry, it is possible to punch the molded parts subsequently or cut them through waterjet cutting. Even machining with saws or milling is possible

  • Edge Finish

    Visible edges can be bordered with different colored ribbons if desired. Even sticking / sewing profiles is possible

  • Assembly

    The parts can be assembled in a variety of ways, for example using zippers, add-on elements and push buttons, or by gluing parts together

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We are often asked this about 3D compression molding

Molds

Tools are always milled from aluminum. For prototypes we mostly use wood or Ureol.

Quantities

The compression molding process is suitable for medium series. It usually makes sense from about 1,000 parts over its runtime

Temperatures

Depending on the material, the temperature is approx. 130°-220°. This ultimately depends on the material and is determined by the thickness, properties and desired properties of the final part.

Development time

Generally it takes 4 weeks after the drawings is final to create a prototype. A series tool takes between 8-10 weeks, so that the first series production can usually start after 12 weeks.