Tooling-driven production. Plastic and metal, qualified to spec.
Replication manufacturing for technical components — thermoplastic injection moulding and pressure die casting under one engineering team. Programs are run from DFM through T1 validation to PPAP-grade production, with mould-flow analysis, dimensional sign-off, and lot-level traceability captured at each gate. Tools designed for cycle-time efficiency and scrap-rate discipline across the lifetime of the program.
- Plastic injection moulding — single-cavity prototype tools through multi-cavity hot-runner production tools, including insert and over-moulded assemblies.
- Pressure die casting — high-pressure casting in zinc, aluminium, and magnesium alloys for structural and housing components.
- Engineering-grade materials — commodity through high-performance thermoplastics, glass-filled and reinforced grades, and certified casting alloys.
- DFM-led tooling — gating strategy, mould-flow simulation, ejection and cooling design reviewed before steel is cut.
- Value-add & assembly — insert installation, secondary machining, finishing, kitting, and sub-assembly integration.
Tooling envelope and tolerance — published.
Two replication processes under one engineering framework. Capabilities below are quoting baselines; tighter limits are achievable per critical feature following process review.
| Parameter | Injection Moulding | Pressure Die Casting |
|---|---|---|
| Clamp tonnage / locking force | 50 – 450 tonnes (above on request) | 50 – 800 tonnes (alloy-dependent) |
| Shot weight / pour weight | up to ~600 g (larger per program) | up to ~3 kg (alloy and machine class) |
| Tool type | Single & multi-cavity, hot-runner, family tools | Single & multi-cavity steel dies, slides & cores |
| Secondary processes | Insert moulding, over-moulding, two-shot (program-dependent) | Trim, shot-blast, machining, surface finishing |
| Dimensional tolerance | DIN 16742 (general); tighter per feature | NADCA Standard (general); tighter per feature |
| Volume band | 1k – 1M+ pcs/year | 1k – 500k+ pcs/year |
| Validation framework | DFM → T1 → PPAP-style | DFM → T1 → PPAP-style |
Materials — qualified by application, not catalogue.
Material grade selected against the operating envelope — temperature, mechanical load, regulatory exposure (RoHS / REACH / FDA / UL where applicable). Mill or alloy certificates supplied on request for regulated programs.
| Family | Grades / Examples |
|---|---|
| Commodity thermoplastics | PP, PE (HD / LD), PS, ABS |
| Engineering thermoplastics | PC, PA6 / PA66, POM (Delrin), PBT, PMMA |
| Filled / reinforced plastics | Glass-filled PA (15–50 % GF), GF-PBT, talc-filled PP, mineral-filled grades |
| High-performance plastics | PEEK, PPS, LCP, PEI (Ultem) — program-dependent |
| Elastomers / TPE | TPU, TPV, TPE-S (over-mould compatible with PA, ABS, PC) |
| Die-cast alloys — zinc | Zamak 3, Zamak 5, ZA-8 — fine detail, low porosity |
| Die-cast alloys — aluminium | ADC12 (A383), ADC10, A380 — structural housings, heat-sink applications |
| Die-cast alloys — magnesium | AZ91D, AM60B (on request) — weight-critical applications |
From DFM through PPAP — gated, documented, signed off.
Every program runs the same four-phase framework regardless of process. Each phase has defined deliverables, acceptance criteria, and customer sign-off before the next phase opens.
DFM & Tool Design
Mould-flow simulation, gating strategy, ejection geometry, and cooling layout reviewed against your part drawing and material specification. Tool concept frozen and signed off before steel is cut.
T1 Trial & Validation
First-off shots evaluated against the controlled drawing — dimensional, visual, and functional. Iteration loop with documented engineering changes until parts pass acceptance criteria for capability study release.
Capability & PPAP
Process capability study (Cp / Cpk on critical features), control plan finalisation, and PPAP-style documentation pack covering material certs, dimensional results, and process settings. Production release on customer sign-off.
Production & Lot Records
Series production with in-process SPC monitoring, end-of-line inspection per control plan, and lot-traceable records (material, machine, operator, shift). Packaging and labelling to your spec.