Manufacture of code discs, pulse discs, reflective discs, rulers, apertures and precision masters for optoelectronic applications
Gebrueder Mayer GmbH
Konstanz (Wollmatinger Str. 70, 78467)New on Amplifa
About Gebrueder Mayer
Gebrueder Mayer GmbH in Konstanz is a specialist operation for code discs, pulse discs, reflective discs, pulse rulers and apertures on a photographic basis for optoelectronic applications in transmitted-light and reflective configurations. Founded in 1958, the company manufactures from prototypes to mass production, achieving resolutions of up to 100,000 dpi and optical tolerances below one micrometer. Manufacturing includes photoplot and direct exposure of film and photoglass (film formats up to 1200 x 1600 mm), lithography, etching of chrome-on-glass and metal, additive electroforming (fine nickel), and CNC milling of complex figures including camera-assisted positioning systems. Materials are polycarbonate (Mayplex-C), Plexiglas HT (Mayplex-M), polyester film, chrome-on-glass, metal and aluminium. Customers include rotary encoder manufacturers worldwide as well as manufacturers of medical devices, optical control and inspection systems and positioning systems. In addition, the company offers CAD design, reproduction services, barcode film masters and EPS files.
- Site
- Konstanz
- Processes
- Manufacture of code discs, pulse discs, apertures and pulse rulers on a photographic basis, CAD design / data creation of film masters, Photoplot / direct exposure of film, Photoplot HR film, Exposure of photoglass, Lithography (Mayplexc), Lithography (Plexiglas), Lithography (film)
- Materials
- Polycarbonate (Mayplex/Mayplexc), Plexiglas HT (Mayplexm), Polyester film, Chrome-on-glass, Metal (fine nickel), Aluminium (hubs), Photoglass, Polycarbonate with photoresist layer
- Certificates
- CCG certification (standards-compliant barcode films)
- Founded
- 1958
- Industries
- Rotary encoder manufacturers, Medical technology, Optical control systems, Optical inspection systems, Positioning systems, Printing industry / barcode
- 01
CAD design / data creation
- 02
Photoplot / direct exposure of film and photoglass
- 03
Repro processing, contact copies, step & repeat
- 04
Lithography / etching / electroforming
- 05
CNC milling of contours
- 06
Assembly (hubs, adhesive films)
Materials and Processes
Polycarbonate with photoresist layer
Proprietary material manufactured since 1995 for code and pulse discs in transmitted light, flexible and usable up to 100 °C.
Plexiglas HT with photoresist layer
Alternative to Mayplex-C, usable up to 85 °C.
Polycarbonate/Plexiglas with reflective layer
For reflective discs in space-critical applications.
Float glass with vapor-deposited chrome layer
Enables etching with slot widths below 0.005 mm at 0.001 mm tolerance.
Polyester film (0.18 mm) with photoresist layer
Classic carrier material variant usable up to approx. 60 °C.
Metal (electroforming)
Additively manufactured parts with slot widths from 0.10 mm.
Aluminium (hubs)
For adhesive-bonded mounting hubs with locking screw.
Photoglass
Carrier material for high-resolution exposures on request.
Location
Konstanz
DEHeadquarters / Manufacturing
- Lot size
- Prototype to mass production
- Materials
- Mayplex-C/M, chrome-on-glass, film, fine nickel, aluminium
- Photoplotter (film up to 1200 x 1600 mm, HR film up to 600 x 850 mm)
- Laser exposure systems
- CNC milling machines
- CNC machines with camera-assisted positioning systems
- CAD system with screen workstations
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of code discs, pulse discs, apertures and pulse rulers on a photographic basisEngineering | optical <1 µm, mechanical <10 µm | – | – | Prototype – Mass production | Polycarbonate (Mayplex), Plexiglas HT (Mayplexm), Film (polyester), Chrome-on-glass |
| CAD design / data creation of film mastersEngineering | – | 1600 mm | – | – | – |
| Photoplot / direct exposure of filmEngineering | bar tolerance 5 µm (barcode) | 1200 mm × 1600 mm | – | – | Film |
| Photoplot HR filmEngineering | – | 600 mm × 850 mm | – | – | HR film |
| Exposure of photoglassEngineering | resolution up to 100,000 dpi | – | – | – | Photoglass |
| Lithography (Mayplexc)Surface | slot width 0.020 mm, tolerance 0.003 mm | – | – | – | Mayplexc (polycarbonate) |
| Lithography (Plexiglas)Surface | slot width 0.025 mm, tolerance 0.005 mm | – | – | – | Plexiglas |
| Lithography (film)Surface | slot width 0.025 mm, tolerance 0.005 mm | – | – | – | Film |
| Etching (chrome-on-glass)Surface | slot width <0.005 mm, tolerance 0.001 mm | – | – | – | Chrome-on-glass |
| Additive (metal, electroforming/fine nickel)Additive | slot width 0.10 mm, tolerance 0.01 mm | – | – | – | Metal, Fine nickel |
| Etching (metal)Surface | slot width 0.12 mm, tolerance 0.01 mm | – | – | – | Metal |
| CNC milling of complex figuresMachining | center bore 0.01 mm | – | – | – | Polycarbonate, Plexiglas |
| Contact copies, step and repeat, repro processingEngineering | – | – | – | – | Film |
| Barcode creation (EPS files and film masters)Engineering | bar tolerance 5 µm | – | – | – | – |
| Prototype printed circuit board production in small and large seriesEngineering | – | – | – | Small series – Large series | – |
5 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC milling machine | – | – | – | – | Konstanz |
| CNC machine with camera-assisted positioning system | – | – | – | – | Konstanz |
| Photoplotter | – | – | Film up to 1200 x 1600 mm, HR film up to 600 x 850 mm | – | Konstanz |
| Laser exposure system | – | – | – | – | Konstanz |
| CAD system with screen workstations | – | – | – | – | Konstanz |
Additional services
Reference customers
Quality
Manufacturing achieves optical tolerances below one micrometer and mechanical tolerances below ten micrometers; center bores are machined with 0.01 mm tolerance. For standards-compliant barcode film masters with 5 µm bar tolerance, the company was awarded the CCG certification.
| Evidence | Konstanz |
|---|---|
| CCG certification (standards-compliant barcode films) |
History
- 1958
Founded by Mr. Mayer sen. for his two sons; developed into a specialist operation for precision masters under the leadership of Helmut E. Mayer
- 1962
Specialization in layouts for printed circuits
- 1963
Artwork creation with ink conductor tracks on aluminium-cardboard circuit boards
- 1965
mayprint: first European manufacturer with over 80 grid types
- 1966
Precision reprography; expansion through customers from optics, metrology, control and satellite technology
- 1967
Circuit prints; precision originals for 20-inch multilayers with 5 µm accuracy
- 1968
maytape production for special symbols; mayscope: special masters such as polar graduations, code discs, rulers
- 1972
In-house production of GM scales in chrome-on-glass
- 1973
Expansion of code and pulse discs as well as pulse rulers
- 1981
Introduction of CAD with own software extension
- 1982
Expansion of prototype printed circuit board production in small and large series (until 2020)
- 1985
Expansion of the CAD system with screen workstations
- 1987
Fusion of EDC + SCS
- 1988
Expansion of new CAD systems; AUTOCAD for special master design
- 1995
Development of the proprietary material Mayplex-C (polycarbonate with photoresist layer)
- 1997
Market launch of Mayplex-C and Mayplex-M
- 2000
Move to larger premises
- 2003
CNC milling machines for complex figures
- 2010
Expansion with CNC machines with camera-assisted positioning systems
- 2015
Expansion of the product range with reflective discs