Injection-molded parts in 1K, 2K and 3K with tooling and series production from a single source, since 1990.
icotek Kunststofftechnik GmbH
GaildorfNew on Amplifa
About icotek Kunststofftechnik
Since 1990, icotek Kunststofftechnik GmbH has been producing technical injection-molded parts in Gaildorf, Baden-Württemberg, using single-, two- and three-component processes as well as insert technology with overmolded metal inserts. The range spans from 0.1 grams to 1.5 kilograms shot weight, from 1 piece with no minimum quantity up into the millions per year. The company accompanies projects from plastics-optimized design and Mold-Flow analysis, through tool design and supervision of mold making, to fully automated series production on 13 injection molding machines with robotic handling, finishing, assembly and logistics per KANBAN, consignment and FIFO. All common thermoplastics except PVC are processed, from PP, ABS and PA6 GF30 to high-performance thermoplastics such as PPS and PEEK as well as elastomers for hard-soft composites. Industries served include automotive accessories, consumer goods, heating, glass fiber, energy, sensor technology, electronics, medical technology, construction, cleaning and ID systems. The owner-managed family business, now in its second generation, is certified to DIN EN ISO 9001.
- Site
- Gaildorf
- Processes
- 1K injection molding, 2K injection molding (two-component), 3K injection molding (three-component, e.g. upper housing ABS+PC+TPE+insert), Insert technology (overmolding of metal inserts such as contacts, threads, bushings), Tool and mold making (design, supervision, prototype/pre-series/series tools), MuCell (physical foaming process), Chemical foaming process with blowing agent (e.g. foamed TPO airbag cover), Gas injection & gas counter-pressure
- Materials
- PP polypropylene (PPH, PPC), PE polyethylene (HD/LD), ABS acrylonitrile-butadiene-styrene, ASA / PC/ASA, PA 6 / PA 6.6 polyamide, PA6 GF30 glass-fiber reinforced, PC polycarbonate, PC/ABS blend (also V0 flame-retardant)
- Certificates
- DIN EN ISO 9001, ISO 9001, IATF 16949, ISO 13485
- Founded
- 1990
- Industries
- Automotive accessories, Consumer/Consumer goods, Cleaning technology, Heating and air conditioning technology, Glass fiber and network infrastructure, Energy and utility technology
- 01
Consulting for plastics-optimized design
- 02
Mold-Flow analyses
- 03
Tool and mold making (design, construction by partners, acceptance, sampling)
- 04
Prototypes via 3D printing
- 05
Injection molding 1K/2K/3K and insert technology
- 06
Finishing, printing, ultrasonic welding, aluminum vapor coating
- 07
Assembly of subassemblies
- 08
Logistics (KANBAN, consignment, FIFO, EDIFACT)
Locations
Gaildorf
DEDevelopment, Production, Quality Assurance, Warehouse
- Part weight / size
- 0.1 g – 1.5 kg shot weight, tool size up to approx. 90 ×
- Lot size
- From 1 piece with no minimum quantity up to 7,000,000 pcs/year per part
- Materials
- All common thermoplastics except PVC, from PP and ABS to PPS and PEEK
- 13 fully automated injection molding machines with robotic handling (1K, 2K, 3K)
- Clamping forces up to 200 t
- Autonomous production cell for multi-component parts
- In-house measuring laboratory
- 3D printing for prototypes
Parts from Ongoing Series
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| 1K injection moldingPlastics | – | – | 0.1 g – 1.5 kg | 1 piece – up to 7,000,000 pcs/year | – |
| 2K injection molding (two-component)Plastics | – | – | 0.1 g – 1.5 kg | 1 piece – up to 7,000,000 pcs/year | ABS, PC, TPE, TPV, ASA, PP, PA |
| 3K injection molding (three-component, e.g. upper housing ABS+PC+TPE+insert)Plastics | – | – | 0.1 g – 1.5 kg | 1,000,000 pcs/year (reference) | ABS, PC, TPE |
| Insert technology (overmolding of metal inserts such as contacts, threads, bushings)Plastics | – | – | 0.1 g – 1.5 kg | – | POM, ABS, PC, TPE |
| Tool and mold making (design, supervision, prototype/pre-series/series tools)Engineering | – | – | – | – | – |
| MuCell (physical foaming process)Plastics | – | – | – | – | – |
| Chemical foaming process with blowing agent (e.g. foamed TPO airbag cover)Plastics | – | – | – | – | TPO |
| Gas injection & gas counter-pressurePlastics | – | – | – | – | – |
| Expancel process (expandable microspheres)Plastics | – | – | – | – | – |
| Finishing and printingSurface | – | – | – | – | – |
| Aluminum vapor coatingSurface | – | – | – | – | – |
| Ultrasonic weldingJoining | – | – | – | – | – |
| Assembly of subassemblies (ready to install)Assembly | – | – | – | – | – |
| Design consulting, Mold-Flow analyses, material selection, metal substitutionEngineering | – | – | – | – | – |
| 3D printing of prototypes (only as a prototyping aid, not as a manufacturing service, samples in 2Additive | – | – | – | – | – |
| First-article inspection, dimensional and visual inspection in own measuring laboratory,Testing | – | – | – | – | – |
| Over moulding (two-stage overmolding of finished parts)Plastics | – | – | – | – | – |
5 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Single-component injection molding machine (fully automated with robotic handling) | – | – | Tool size up to approx. 90 × 130 cm; shot weight 0.1 g to 1.5 kg | – | Gaildorf |
| Two-component injection molding machine (multi-component) | – | – | Shot weight 0.1 g to 1.5 kg | erste Mehr | Gaildorf |
| Three-component injection molding machine (multi-component) | – | – | Shot weight 0.1 g to 1.5 kg | – | Gaildorf |
| Injection molding machines total fleet (all fully automated with robotic handling) | – | 13 | Clamping force tonnages up to 200 t (expansion 2005) | – | Gaildorf |
| Autonomous production cell for multi-component parts | – | 1 | – | 2015 | Gaildorf |
Additional services
Reference customers
Quality Assurance
Quality management is certified to DIN EN ISO 9001. In the company's own measuring laboratory, in operation since 2006, first-article inspections, dimensional and visual inspections, and process-accompanying checks are carried out with traceable documentation.
| Evidence | Gaildorf |
|---|---|
| ISO 9001 | |
| IATF 16949 | |
| ISO 13485 |
History
- 1990
Founding of icotek Kunststofftechnik in Gaildorf
- 1997
Construction of an own production hall, first multi-component machine
- 2005
Expansion with a warehouse, machine fleet expanded up to 200 t clamping force
- 2006
Establishment of an in-house measuring laboratory
- 2010
Construction of a second warehouse
- 2015
Implementation of an autonomous production cell for multi-component parts
- 2024
Succession arrangement, transition to the second generation of the Bethke family