Case study Succesful partnership
The fischer group has collaborated with Mold-Masters on a special project. The construction of a mould solution has been a success story for both companies.
The fischer group of companies is an international corporation based in Waldachtal, Germany. The headquarters of fischer automotive systems in Horb am Neckar, Germany, are also home to fischer tool and mould-making, which not only acts as an internal toolmaker and supplier to the various divisions of fischer, but has also been successfully supporting external companies with injection moulding tools for thermoplastics and thermoset plastics as well as cutting dies and turn-key solutions for the past four years. fischer tool and mould-making also produced the tool needed to manufacture the award-winning fischer Duopower dowel. In addition to the high quality requirements of the Duopower, the greatest challenge was the constructive two-component mould solution, the precision of the components and the requirements for the hot runner system.
The fischer Duopower is part of the portfolio of high-quality solutions available from fischer fixing systems. The two-component dowel expands into concrete and solid building blocks and unfolds into perforated building blocks and panel building materials. These properties make the fischer Duopower a versatile expert among standard dowels, opening up a completely new performance class in dowel-fixing. fischer created the tool, as a specialist for high-cavity multi-component tools as it was obvious that perfect material processing through reliable injection moulding is required in the production process. The key elements are the precisely matched mould and the hot runner system. Mold-Masters temperature control and process control systems supplied the right solution for manufacturing the fischer Duopower. At its European headquarters in Baden-Baden, Germany, Mold-Masters develops and produces hot runner solutions that optimise injection moulding processes, achieve higher efficiency and reduce plastic waste. For the production of the Duopower, fischer tool and mould-making developed and produced a two-component mould in order to process both material components (polyamide and polypropylene) in one hot runner mould. Mold-Masters’ Master-Series systems offer great thermal precision and system balancing thanks to their brazed heater technology. In combination with the Master-Series nozzles, minimum pitches in the hot runner mould have been made possible. The homogeneous heat profile produces parts of the best possible quality and exceptional durability – a perfect fit for moulding the Duopower dowels.
Life cycle management
After commissioning the series production mould, it became apparent that the application with the long, narrow nozzles was technically complex and demanding. Nevertheless, fast cycle times and precise part quality must be maintained, downtimes and unplanned interruptions to operation must be avoided. In order to extend the entire life cycle of the hot runner mould and maximise part output, the Mastercare service team at Mold-Masters evaluated the various needs and requirements for the highest possible productivity level of the multi-function dowel. To this end, a customer-specific maintenance contract was set up as part of a comprehensive Life Cycle Management programme (production guarantee) to optimally complement the co-operation between fischer and Mold-Masters. Mold-Masters’ Life Cycle Management programme is a modular service that can be specifically tailored to the customer’s needs. At fischer, the hot runner moulds have been classified into various risk groups. Original spare parts required are included and kept in stock. Continuous maintenance is carried out globally at appropriate intervals and reduces the risk of failure to a minimum. Maintenance and service costs are efficiently calculated and processes defined in a single contract. This avoids unnecessary administrative effort and ensures a fast Mastercare service team response time. Markus Pollidio, Head of Aftersales Mastercare Europe at Mold-Masters, confirms: “As a service partner, our team always works with full energy to achieve maximum customer satisfaction.” The comprehensive range of services offered to fischer provides fast and worldwide customer support, higher productivity and safety, as well as significant cost reductions.
Meanwhile, more than 20 hot runner moulds with a maintenance contract from Mold-Masters are in worldwide use for the fischer group of companies. Further hot runner systems are successively being equipped with maintenance contracts. A reliable partnership has been established based on the comprehensive Mold-Masters service and support programmes. Additional co-development also resulted from this partnership. Both companies want to further expand their co-operation for mutual benefit in the long term.