As a specialist in polyurethane moulded parts, Emaform AG is there every step of the way from product development to series production. Our customer service team supports you in the design of PUR housings, the selection of materials and the cost-effective optimisation of your technical moulded parts. With decades of experience in the polyurethane sector, we find tailor-made solutions for your individual requirements, from prototypes to series production.
Emaform AG’s advisory services include material evaluation, material samples and professional support when designing your PUR moulded parts. We provide you with 3D data, make prototypes and check the technical feasibility and cost-effectiveness of your project. In this way, we guarantee a cost-efficient solution for your customer-specific polyurethane housings and technical moulded parts right from the outset.
Based on your specifications, we develop an economically optimised concept for your moulded part. We show you alternative solutions, optimise costs and prepare a transparent offer. In addition, you receive sound recommendations on design, and we jointly define the relevant test dimensions and review supplementary work processes. In doing so, we lay the foundations for efficient and high-quality production.
The wall thicknesses can vary greatly when using integral foams (there are hardly any recesses on the surface). When using compact materials, wall thicknesses that are as uniform as possible are advantageous. With both materials, it should be noted that different wall thicknesses can lead to deformations of the moulded parts due to uneven shrinkage. The size, geometry and application of the moulded part essentially determine the wall thickness.
The wall thicknesses can vary greatly when using integral foams (there are hardly any recesses on the surface). When using compact materials, wall thicknesses that are as uniform as possible are advantageous. With both materials, it should be noted that different wall thicknesses can lead to deformations of the moulded parts due to uneven shrinkage. The size, geometry and application of the moulded part essentially determine the wall thickness.
When designing a moulded part, care must be taken to ensure that the tool can be produced economically while still ensuring efficient and high-quality production. In general, up to 20,000 pieces can be made from one mould without special maintenance work.
While lateral sliders and loose parts are contemporary features, they make mould construction – and also the moulded parts in some cases – considerably more expensive, and may reduce the service life of the tool.
Particularly in the case of free-form surfaces, the use of 3D CAD data is unavoidable. For mould construction, we prefer to use 3D IGES data, Parasolid or SolidWorks data. Other data formats are possible, but must be agreed in advance. It is important to ensure that the data matches the blank. In case of critical tolerances, the thickness of the coating must be taken into account!
When designing a moulded part, care must be taken to ensure that the tool can be produced economically while still ensuring efficient and high-quality production. In general, up to 20,000 pieces can be made from one mould without special maintenance work.
While lateral sliders and loose parts are contemporary features, they make mould construction – and also the moulded parts in some cases – considerably more expensive, and may reduce the service life of the tool.
Particularly in the case of free-form surfaces, the use of 3D CAD data is unavoidable. For mould construction, we prefer to use 3D IGES data, Parasolid or SolidWorks data. Other data formats are possible, but must be agreed in advance. It is important to ensure that the data matches the blank. In case of critical tolerances, the thickness of the coating must be taken into account!
A mould angle or mould inclination of 1° or more is always desirable and makes the removal of the moulded part from the tool much easier. A smaller (or no) angle is possible, but this must be discussed with us. The angle should already be included in the 3D CAD data. Here too, we recommend consulting with us in advance.
A mould angle or mould inclination of 1° or more is always desirable and makes the removal of the moulded part from the tool much easier. A smaller (or no) angle is possible, but this must be discussed with us. The angle should already be included in the 3D CAD data. Here too, we recommend consulting with us in advance.
Radii increase the fracture strength of moulded parts and reduce the cost of mould production. As a rule, the larger the radius, the better. Sharp edges are only easier to produce than rounded edges along the mould separation line. After coating, sharp edges result in radii of approx. 0.5 mm.
Radii increase the fracture strength of moulded parts and reduce the cost of mould production. As a rule, the larger the radius, the better. Sharp edges are only easier to produce than rounded edges along the mould separation line. After coating, sharp edges result in radii of approx. 0.5 mm.
Ribs measuring ± 50% the wall thickness allow for optimal stability of the moulded parts without sink marks on the visible sides. If possible, the ribs should run in the same direction as the foaming in order to avoid air pockets.
Ribs measuring ± 50% the wall thickness allow for optimal stability of the moulded parts without sink marks on the visible sides. If possible, the ribs should run in the same direction as the foaming in order to avoid air pockets.
Thread inserts cast in brass are most common (different products, usually manufacturer-specific).
When inserting metal parts for reinforcement, care must be taken to ensure that there is no intolerable distortion of the moulded parts and that no stresses occur that would lead to damage.
Thread inserts cast in brass are most common (different products, usually manufacturer-specific).
When inserting metal parts for reinforcement, care must be taken to ensure that there is no intolerable distortion of the moulded parts and that no stresses occur that would lead to damage.
Threaded bushings are usually used for detachable connections, the most reliable are cast thread inserts (see also ep-FIX), and different types of expansion bushings can also satisfy limited requirements.
Self-tapping screws (PT screws) can also be screwed into pre-cast holes for connections that are only detached rarely. In the case of compact material, this also works with subsequently drilled holes.
Bonding can also lead to good connections between PUR moulded parts and between PUR moulded parts and foreign elements. In the latter case, the different thermal expansion of the various materials must be taken into account. When it comes to the choice of adhesive, the manufacturers of the moulded parts make recommendations depending on the application.
Threaded bushings are usually used for detachable connections, the most reliable are cast thread inserts (see also ep-FIX), and different types of expansion bushings can also satisfy limited requirements.
Self-tapping screws (PT screws) can also be screwed into pre-cast holes for connections that are only detached rarely. In the case of compact material, this also works with subsequently drilled holes.
Bonding can also lead to good connections between PUR moulded parts and between PUR moulded parts and foreign elements. In the latter case, the different thermal expansion of the various materials must be taken into account. When it comes to the choice of adhesive, the manufacturers of the moulded parts make recommendations depending on the application.
Different variants of a moulded part can be created either by interchangeable inserts in the tool or by subsequent CNC machining.
Interchangeable inserts are preferred for geometries with more significant deviations and for clearly defined quantities of the variants, while CNC machining offers more flexibility and can be easily adapted if required.
Different variants of a moulded part can be created either by interchangeable inserts in the tool or by subsequent CNC machining.
Interchangeable inserts are preferred for geometries with more significant deviations and for clearly defined quantities of the variants, while CNC machining offers more flexibility and can be easily adapted if required.
In general, we attach a label with the Emaform mould number and the production month on the moulded part. Further markings (customer name, customer item number, PUR signet, etc.) can be added on request. Please note that these markings are only possible in the direction of removal from the mould.
In general, we attach a label with the Emaform mould number and the production month on the moulded part. Further markings (customer name, customer item number, PUR signet, etc.) can be added on request. Please note that these markings are only possible in the direction of removal from the mould.
In general, we adhere to the DIN ISO 20457 plastics standard and tolerance group TG5.
Tighter tolerances are possible, but involve additional costs. Special tolerances must be checked carefully with the manufacturer for feasibility before mold production. Asymmetrical tolerances cannot be taken into account directly in today's mold making based on 3D data. Likewise, the layer thickness of the paint coating is not taken into account in mold making (raw part corresponds to 3D data).
Wherever play is required for assembly, too much play rather than too little should be provided for during design. A subsequent reduction in play always means the tool has to be milled again, but if there is too little play then there is no material left on the tool to work with!
In general, we adhere to the DIN ISO 20457 plastics standard and tolerance group TG5.
Tighter tolerances are possible, but involve additional costs. Special tolerances must be checked carefully with the manufacturer for feasibility before mold production. Asymmetrical tolerances cannot be taken into account directly in today's mold making based on 3D data. Likewise, the layer thickness of the paint coating is not taken into account in mold making (raw part corresponds to 3D data).
Wherever play is required for assembly, too much play rather than too little should be provided for during design. A subsequent reduction in play always means the tool has to be milled again, but if there is too little play then there is no material left on the tool to work with!
The shrinkage of the material in the production process is between 5‰ and 8‰ depending on the material and moulded part. This shrinkage does not have to be taken into account in the CAD data supplied by the customer. The necessary corrections are made during mould construction.
The shrinkage of the material in the production process is between 5‰ and 8‰ depending on the material and moulded part. This shrinkage does not have to be taken into account in the CAD data supplied by the customer. The necessary corrections are made during mould construction.
By adding flame retardants (ammonium polyphosphate), compliance with the American UL 94 V0 standard can be achieved.
Integral rigid foam meets the standard with a wall thickness of 5.9 mm or greater. Compact material meets the standard with a wall thickness of 3.1 mm or greater.
By adding flame retardants (ammonium polyphosphate), compliance with the American UL 94 V0 standard can be achieved.
Integral rigid foam meets the standard with a wall thickness of 5.9 mm or greater. Compact material meets the standard with a wall thickness of 3.1 mm or greater.
As a thermosetting plastic, polyurethane has very good chemical resistance due to its chemical structure. Combined with a coating system that is also based on PUR, this means that it can be used in the laboratory or medical sector without any problems. There are resistance tests for common chemicals, and special chemical requirements can also be tested.
As a thermosetting plastic, polyurethane has very good chemical resistance due to its chemical structure. Combined with a coating system that is also based on PUR, this means that it can be used in the laboratory or medical sector without any problems. There are resistance tests for common chemicals, and special chemical requirements can also be tested.
Painting in a RAL colour with a light texture facilitates production and contributes to products that are very easy to care for. In most cases, it is sufficient to paint the visible sides. Special paints (smooth, high-gloss and special effect paints) or coatings (e.g. EMC coating with copper-silver conductive coating) can also be used, but are usually more expensive. If certain areas have to remain unpainted or where paint mist is not permitted, additional masking work is necessary. In the case of tight tolerances, the thickness of the paint coating must be taken into account in the design data and discussed with the manufacturer.
Painting in a RAL colour with a light texture facilitates production and contributes to products that are very easy to care for. In most cases, it is sufficient to paint the visible sides. Special paints (smooth, high-gloss and special effect paints) or coatings (e.g. EMC coating with copper-silver conductive coating) can also be used, but are usually more expensive. If certain areas have to remain unpainted or where paint mist is not permitted, additional masking work is necessary. In the case of tight tolerances, the thickness of the paint coating must be taken into account in the design data and discussed with the manufacturer.
The thermal conductivity of integral PUR rigid foam depends on the bulk density. This is usually around 500 to 600 kg/m3. The density of compact material is approx. 1,050 kg/m3 and therefore cannot reach the insulation values of integral foam. When it comes to sound insulation, both materials are significantly better than comparable solutions made of sheet material.
The thermal conductivity of integral PUR rigid foam depends on the bulk density. This is usually around 500 to 600 kg/m3. The density of compact material is approx. 1,050 kg/m3 and therefore cannot reach the insulation values of integral foam. When it comes to sound insulation, both materials are significantly better than comparable solutions made of sheet material.