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Case Studies

Our case studies provide you with a direct insight into what we are capable of achieving. Discover how you can benefit from our combination of technological expertise, industry knowledge and development skills.

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Consistent quality on the assembly line

Founded in the 1940s, German company burgbad started out as a manufacturer of wooden building blocks and coffee grinders. The company then went on to produce functional bathroom furniture from 1966. Today, burgbad is known not only for its high-quality products that are “Made in Germany”, but also for its sustainable production and delivery processes – as demonstrated by accolades such as being named the first climate-neutral bathroom furniture manufacturer in the world.

  • Robotics Robotics
Medical Technology

Innovation meets quality

The high-quality dental materials, innovative methods of application and treatment concepts developed by Hamburg-based DMG Chemisch-Pharmazeutische Fabrik GmbH are used by dentists and dental laboratories in more than 80 countries. DMG is known for "Made in Germany" quality in a range of areas including the innovative microinvasive treatment of caries without drilling. In toolcraft, DMG found a reliable component manufacturing partner.

  • Injection Moulding + Mould Making Injection Moulding + Mould Making
  • Robotics Robotics
Security

Stringent security requirements

Founded as “Rheinische Metallwaaren- und Maschinenbaufabrik Actiengesellschaft” in 1889, Rheinmetall AG is today an international integrated technology group. The company is a partner and supplier to the automotive industry as well as a global leader in the provision of security technology systems. Rheinmetall AG commissioned toolcraft as a manufacturing partner after being awarded a contract from the German armed forces.

  • Additive Manufacturing Additive Manufacturing
Medical Technology

Filigree and precise

Having already worked with Sivantos for many years, toolcraft stepped in when WS Audiology (WSA) was looking for a component supplier for its in-ear hearing aids. It was crucial that toolcraft could take care of the entire process chain.

  • Injection Moulding + Mould Making Injection Moulding + Mould Making
Medical Technology

Perfectly fitted

The reha team Nordbayern Gesundheitstechnik GmbH is active in the areas of rehabilitation and orthopaedic technology and operates 17 medical supply stores. In order to be able to produce individual orthopaedic aids efficiently, toolcraft was commissioned by reha team to implement a robotic milling process in collaboration with Stäubli.

  • Robotics Robotics
Special machinery manufacturing

Precisely positioned

The family-run company Speck Pumpen Walter Speck GmbH & Co. KG has been manufacturing pumps and compressors for a range of industrial applications for over 100 years. Some of its pumps are fitted with magnetic couplings. To help the company place magnets inside its magnetic holders, toolcraft designed, developed and programmed an automation system and installed it on Speck Pumpen’s premises.

  • Robotics Robotics
Medical Technology

The force of attraction

For ten years, the Section of Experimental Oncology and Nanomedicine (SEON) at the Department of Otorhinolaryngology - Head and Neck Surgery at the University of Erlangen has been researching innovative diagnostic and treatment methods. One of the techniques developed here by senior doctor Prof. Dr. med. Christoph Alexiou and his team is the magnetic drug targeting (MDT) drug delivery system. With the help of an innovative magnetic robot, the active substance can be transported directly to the areas requiring treatment.

  • Robotics Robotics
Medical Technology

Keeping a handle on everything

As a leading supplier of motor systems, Aesculap sells products for use in various areas of medicine, such as orthopaedics, traumatology, heart surgery and dermatology. One such example is its battery-operated motor system Acculan. To produce the battery casing for this motor system, toolcraft used additive manufacturing.

  • Additive Manufacturing Additive Manufacturing
Automotive, vehicle technology and motorsports

Full speed ahead

The concept "Hyperloop" envisions a high-speed train gliding through a vacuum tube and transporting people to their destination in pods travelling at roughly the speed of sound. Since 2015 an international competition has been held in which teams of students design their own pods to race against each other. toolcraft has already supported the project several times by supplying the team of the TU Munich with parts used to construct the pods.

  • Machining Machining
Medical Technology

Micro-plastic components - at the push of a button

For Sonova Holding AG, toolcraft has realized a fully automated production of cerumen filters for hearing aids plus dispenser system. All challenges - tool micro injection moulding, automation robotics, optical component testing - were mastered from one source.

  • Injection Moulding + Mould Making Injection Moulding + Mould Making
  • Robotics Robotics
Others

Production of furniture 4.0

For the automation of manual processes, toolcraft implemented two robotic solutions for the bathroom furniture manufacturer Sanipa that are unique in the industry: 1 picking robot for gripping and feeding components and 1 robot cell for assembling drawers.

  • Robotics Robotics
Optical industry

Mould with an optimised topology

In an internal project we developed and implemented a mould for manufacturing a plastic part for the optical industry. The 3D-printed, topology-optimized result: 50% less mass and 30% faster cycle time with the same component quality.

  • Additive Manufacturing Additive Manufacturing
  • Injection Moulding + Mould Making Injection Moulding + Mould Making
Others

Embossing plate processing - fully automated

To make metal signs even more efficient to manufacture, the toy manufacturer Schopper commissioned us with a robotics solution for the embossing plates required for this purpose. From hardware to offline programming, toolcraft needed 20 weeks for the project.

  • Robotics Robotics
Automotive, vehicle technology and motorsports

Reducing the assembly time

The redesign of a turbine blade wheel has reduced the installation work required for replacement and increased the output of the steam generator. Deutsche Bahn used our complete additive process chain for the project.

  • Additive Manufacturing Additive Manufacturing
Medical Technology

Internally cooled bone drill for the operating theatre

On behalf of the IFW of the University of Hanover, toolcraft developed and manufactured a bone drill with closed internal cooling using 3D printing. This prevents both temperature-related tissue damage and the escape of cooling fluid.

  • Additive Manufacturing Additive Manufacturing
Automotive, vehicle technology and motorsports

Lower weight without a drop in performance

The motor sports university group of the FAU Erlangen-Nuremberg commissioned toolcraft with the design and 3D printing of an engine bracket. By topology optimization a maximum weight and component reduction was achieved with the same fatigue strength.

  • Additive Manufacturing Additive Manufacturing
Automotive, vehicle technology and motorsports

Automated processing of high-quality plastic parts

For NIFCO KTW GmbH, toolcraft has realized a robot cell that processes high-quality coatings of interior plastic components in the visible area of vehicles. The complete solution achieves an accuracy of +/- 0.1 mm.

  • Robotics Robotics
Medical Technology

Micro-precision parts in two-component design

High-precision parts of smallest dimensions, a demanding hard/soft material combination, tightest clearance - for the innovative housing of a hearing aid, we have demonstrated our competence not only in mould making, but also in contract moulding.

  • Injection Moulding + Mould Making Injection Moulding + Mould Making
Automotive, vehicle technology and motorsports

Grinding and polishing robotics for ceramic parts

In partnership with Oechsler AG, toolcraft achieved a unique milestone: In order to grind and polish the ceramic component for the gear lever display and the parking and menu buttons, the most complex machining processes were automated.

  • Robotics Robotics
Automotive, vehicle technology and motorsports

Lotus valve covers - reverse engineered

On behalf of Komo-Tec GmbH, toolcraft took over the reverse engineering of valve covers which are installed in Lotus engines. Thanks to GOM-Optometry, the required 3D files could be "reconstructed" from an existing hardware component.

  • Machining Machining
Automotive, vehicle technology and motorsports

Groove ring made from nitrided steel - the heat treatment challenge

For the turbocharger of a diesel-powered train from ABB Turbo Systems, we realized a groove ring made from nitrided steel that is difficult to machine. The chemical and physical material changes during heat treatment required extensive testing.

  • Machining Machining
Optical industry

Complex camera components made of titanium

Under high time pressure toolcraft produced high-precision exterior and interior components for a special model of the Leica M9 digital camera. In spite of the titanium material and sometimes extremely complex component geometries, the delivery date was never compromised.

  • Machining Machining
Aerospace

Structural lightweight components for aircraft structures

On behalf of Premium Aerotec GmbH we deliver struts, connection and node elements for the fuselage of Airbus A350 and A400M. With a high vertical manufacturing depth, the components are manufactured at extreme machining rates of up to 90 percent with zero distortion.

  • Machining Machining
Aerospace

Quality takes off

The design was fully evaluated, optimised and qualified, using advanced metrology as a fundamental cornerstone of an efficient total solution from the initial concept to the finished part.

  • Machining Machining
Automotive, vehicle technology and motorsports

Laser melted pins with internal cooling

The plants of Adolf Föhl GmbH + Co KG supply several hundred million zinc diecastings and plastic injection mouldings each year. This enormous output indicates the dimension of the increase in productivity which the company way able to achieve thanks to toolcraft's metal laser melting technology.

  • Additive Manufacturing Additive Manufacturing
  • Injection Moulding + Mould Making Injection Moulding + Mould Making

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