Design, mould making and technical plastic injection moulding – parts from 0.1 to 300 g with proprietary thin-wall technology.
HANS FLEIG GmbH
Lahr / Black Forest (Lahr-Kuhbach)New on Amplifa
Design, mould making and injection moulding from a single source
HANS FLEIG GmbH is a family-owned company from Lahr in the Black Forest with more than half a century of experience in design, mould making and technical plastic injection moulding. The company produces injection-moulded parts from 0.1 to 300 grams on machines with clamping forces of up to 2,000 kN in three-shift operation. A particular expertise lies in its own patented thin-wall technology with differential injection, with which wall thicknesses of 0.3 mm at flow lengths of 50 mm and more are produced with process reliability. The value chain ranges from plastics-optimised part design, in-house mould making (30–40 moulds per year in hardened steel) and series production to insert technology, assembly with leak testing and contract manufacturing. Customers come from automotive, packaging, medical and health technology, electronics, the food industry and household appliances. In addition, Fleig develops and sells its own products such as reusable cups and dosing spoons and operates regranulation of plastic waste.
- Site
- Lahr / Schwarzwald
- Processes
- Plastic injection moulding (micro, mini and midi sector), Thin-wall technology in technical plastic injection moulding (differential injection), Packaging injection moulding (packaging machine: cups and bowls), Insert technology / overmoulding of insert parts (cable harnesses, plugs, sockets, magnets), Mould making (single-cavity moulds, hardened steel, 30-40 moulds/year), Design and part engineering (3D-CAD/CAM, DXF and IGS interfaces), Contract manufacturing: milling, turning, grinding, wire cutting of steel, copper or plastic parts, Assembly (fully automatic O-ring fitting, leak testing)
- Materials
- PA (polyamide), PC (polycarbonate), PC/ABS, PTB, LCP (Liquid Crystal Polymer), PA12 (unfilled), Polypropylene (PP), Bio-based, industrially compostable plastic
- Certificates
- ISO 9001:2015, IATF 16949:2016, ISO 14001:2015, EN 9100, ISO 13485
- Employees
- 38
- Industries
- Automotive, Packaging, Medical and health technology, Electronics/Electrical engineering, Food, Household appliances
- 01
Design and part engineering (3D-CAD/CAM)
- 02
Mould making in hardened steel
- 03
Plastic injection moulding incl. thin-wall technology
- 04
Insert technology / overmoulding
- 05
Assembly and leak testing
- 06
Quality assurance
- 07
Regranulation / recycling
Materials and processes
Polyamide (PA)
Engineering plastic for thin-walled, mechanically stressed components in thin-wall injection moulding.
Polycarbonate (PC)
Tough, transparent material for functional and optical components.
PC/ABS blend
Combination of stiffness and toughness for technical housing parts.
PTB
Engineering plastic used in the thin-wall technology process.
Liquid Crystal Polymer (LCP)
High-performance plastic for precise, thin-walled components with tight tolerances.
PA12 (unfilled)
Unfilled material used in thin-wall injection moulding.
Polypropylene (PP)
Material for cups, bowls and everyday products of the own brands.
Food-grade plastic (FDA-certified)
For food contact such as dosing spoons and coffee-to-go cups.
Through-hardened steel
Tool steel for long-lasting forming elements of the injection moulds.
Steel
Parts milled, turned, ground and wire-cut in contract manufacturing.
Copper
Material machined in contract manufacturing.
Bio-based, industrially compostable plastic
For the reusable cup, which is 100 % industrially compostable.
Locations
Lahr / Black Forest
DEHeadquarters, production, mould making, administration
- Part weight / size
- Injection-moulded parts 0.1–300 g; wall thicknesses down to
- Lot size
- Prototypes to large-scale series
- Materials
- PA, PC, PC/ABS, PTB, LCP, PA12, PP, food-grade plastics
- 32 injection moulding machines with clamping forces of 22–200 t
- 3 Arburg machines with 1,500 kN
- 2 Boy systems up to 900 kN
- Hermle 5-axis machining centre
- 2 CNC milling machines
- 2 CNC surface grinding machines
- CNC wire-cutting machine
- CNC die-sinking EDM machine
- Measuring machine
- Ultrasonic welding system
- Packaging machine
- 8 assembly machines
- Formlabs Form 4L 3D printer
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Plastic injection moulding (micro, mini and midi sector)Plastics | Runout tolerance of a few hundredths of a millimetre | – | 0.1 g – 300 g | Prototypes – Large-scale series | PA, PC, PC/ABS, PTB, LCP, food-grade plastic |
| Thin-wall technology in technical plastic injection moulding (differential injection)Plastics | Runout tolerance of a few hundredths of a millimetre | – | 300 g | Large-scale series | PA, PC, PC/ABS, PTB, LCP, PA12 |
| Packaging injection moulding (packaging machine: cups and bowls)Plastics | – | – | 150 g | – | food-grade plastic (FDA-certified) |
| Insert technology / overmoulding of insert parts (cable harnesses, plugs, sockets, magnets)Plastics | – | – | 300 g | – | Metal pins, Threaded inserts, Nuts, Plain bearings, Sheet metal parts, Magnets |
| Mould making (single-cavity moulds, hardened steel, 30-40 moulds/year)Engineering | – | – | 0.01 g – 175 g | Small series – production runs in the millions | through-hardened steel |
| Design and part engineering (3D-CAD/CAM, DXF and IGS interfaces)Engineering | – | – | – | – | – |
| Contract manufacturing: milling, turning, grinding, wire cutting of steel, copper or plastic partsMachining | – | – | – | – | Steel, Copper, Plastic |
| Assembly (fully automatic O-ring fitting, leak testing)Assembly | – | – | – | – | – |
| Assembly technology on 8 assembly machines with camera and laser technology (100 % leak andAssembly | – | – | – | – | – |
| Quality assuranceTesting | – | – | – | – | – |
| Laser welding films in thin-wall injection mouldingPlastics | – | – | – | – | engineering plastics |
| 3D printing (Formlabs Form 4L)Additive | – | – | – | – | – |
| Regranulation of plastic waste into granulatePlastics | – | – | – | – | Plastic |
28 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Injection moulding machine | – | 3 | Clamping force 22 t | – | Lahr |
| Injection moulding machine | – | 5 | Clamping force 35 t | – | Lahr |
| Injection moulding machine | – | 4 | Clamping force 40 t | – | Lahr |
| Injection moulding machine | – | 4 | Clamping force 50 t | – | Lahr |
| Injection moulding machine | – | 3 | Clamping force 55 t | – | Lahr |
| Injection moulding machine | – | 1 | Clamping force 60 t | – | Lahr |
| Injection moulding machine | – | 3 | Clamping force 100 t | – | Lahr |
| Injection moulding machine | – | 7 | Clamping force 150 t | – | Lahr |
| Injection moulding machine | – | 2 | Clamping force 200 t | – | Lahr |
| Injection moulding machine | Arburg | 3 | Clamping force 1,500 kN | 2013 | Lahr |
| Injection moulding machine | Dr. Boy | 2 | Clamping force up to 900 kN | 2011 | Lahr |
| 5-axis machining centre | Hermle | 1 | – | – | Lahr |
| CNC milling machine | – | 2 | – | – | Lahr |
| Conventional milling machine | – | 2 | – | – | Lahr |
| Conventional lathe | – | 2 | – | – | Lahr |
| CNC wire-cutting machine | – | 1 | – | – | Lahr |
| CNC die-sinking EDM machine | – | 1 | – | – | Lahr |
| Measuring machine | – | 1 | – | – | Lahr |
| CNC surface grinding machine | – | 2 | – | – | Lahr |
| Starting-hole machine | – | 1 | – | – | Lahr |
| Ultrasonic welding system | – | 1 | – | – | Lahr |
| Band saw | – | 2 | – | – | Lahr |
| Cut-off machine | – | 1 | – | – | Lahr |
| Pillar drilling machine | – | 1 | – | – | Lahr |
| Sandblasting unit | – | 1 | – | – | Lahr |
| Packaging machine | – | – | – | – | Lahr |
| 3D printer | Formlabs Form 4L | – | – | – | Lahr |
| Assembly machine | – | 8 | – | seit 2001 | Lahr |
Additional services
Reference customers
Quality and certification
Production is certified to ISO 9001:2015, IATF 16949:2016 and ISO 14001:2015; all production and handling processes are documented throughout. On assembly machines with camera and laser technology, 100 % leak and function tests are performed.
| Evidence | Lahr / Black Forest |
|---|---|
| ISO 9001:2015 | |
| IATF 16949:2016 | |
| ISO 14001:2015 | |
| EN 9100 | |
| ISO 13485 |
History
- 2001
Start of assembly technology: since then, eight assembly machines have been running for fully automatic O-ring fitting.
- 2006
Quality management certification.
- 2007
New production hall with 750 sqm; doubling of injection moulding capacity.
- 2009
Completion of the AiF-funded project on thin-wall technology; presentation at Fakuma and EuroMold.
- 2010
Fully automatic insertion of inserts and turned parts in control elements for adaptive cornering light control.
- 2011
Two new systems from Dr. Boy up to 900 kN; magnetic sensor project (start-stop system).
- 2012
Start of the tyre pressure sensor project.
- 2013
Three new Arburg injection moulding machines with 1,500 kN; series production of the thin-wall technology.
- 2014
Seal of quality "Innovative through Research" from the Donors' Association for the Promotion of Sciences and Humanities in Germany; two new systems for ignition coil bodies.
- 2015
Expansion of production space; market launch of the table floor protector for beer garden furniture (first in-house development).
- 2017
Award as one of the "100 companies for resource efficiency" in Baden-Württemberg.
- 2018
Seal of quality "Innovative through Research" (third time after 2014 and 2016); certification to IATF 16949.
- 2019
Prize winner of the "Großer Preis des Mittelstands" (Grand Prize of SMEs) of the Oskar-Patzelt-Foundation at state level.