Development, design and construction of special machinery, special gearboxes, test rigs and fixtures through to production readiness.
iW Maschinenbau GmbH
Niestetal (near Kassel)New on Amplifa
Everything from a single source: from prototype to production readiness
iW Maschinenbau GmbH, based in Niestetal near Kassel, is a mechanical engineering company focused on planning, development and project management. The company supports custom development tasks from prototype construction through to production readiness, providing services such as design, mechanical engineering calculations, simulation (FEM, MBS), strength verification in accordance with the FKM guideline, metrology, 3D printing, documentation, manufacturing, assembly and commissioning. Its fields of activity include drive technology, handling technology, special gearbox construction, special machinery construction, test rig construction, automation technology as well as equipment and fixture design. For 3D printing, the FDM build process is used to process plastics such as Onyx and Nylon as well as fibre-reinforced materials (glass fibre, Kevlar, carbon fibre, HSHT glass fibre) on Markforged printers; steel, aluminium and cast materials are used for strength verifications. Customers come from the medical, defence, aerospace, research and development, and general mechanical engineering sectors; among other things, a calibration test rig for the actuators of the A380 flaps was developed.
- Site
- Niestetal
- Processes
- Development/design, Calculation (KISSSOFT, gearbox/gear design), Simulation (FEM, MBS), Strength verification according to FKM guideline, Metrology / measurement data recording, 3D printing (FDM build process) of thermoplastic functional models, prototypes and small series, Documentation, Commissioning
- Materials
- Onyx, Nylon, Glass fibre, Kevlar, Carbon fibre, HSHT glass fibre, Steel, Aluminium
- Certificates
- ISO 9001
- Founded
- 1980
- Industries
- Medical, Defence, Aerospace, Research and development, General mechanical engineering
- 01
Project management
- 02
Development/design
- 03
Calculation (KISSsoft)
- 04
Simulation (FEM, MBS)
- 05
Strength verification (FKM)
- 06
3D printing / prototype construction
- 07
Manufacturing
- 08
Assembly and functional testing
- 09
Documentation / CE documentation
- 10
Commissioning
Materials and processes
3D printing (FDM, Markforged)
Production of thermoplastic functional models, prototypes and small series, including with complex geometries.
Onyx (plastic)
Strong thermoplastic with high flexural strength (flexural strength 81 MPa), can be reinforced with continuous fibres.
Nylon (plastic)
Flexible, impact-resistant thermoplastic for applications requiring greater flexibility or low friction.
Glass fibre
Continuous fibre with high strength (flexural strength 210 MPa) for robust tools.
Kevlar
Lightweight, durable fibre for parts subjected to repeated and sudden loads, e.g. robot gripper tools.
Carbon fibre
Fibre with the highest strength-to-weight ratio, replacing machined aluminium parts.
HSHT glass fibre
Fibre with high strength and heat tolerance for parts under high operating temperatures.
Steel
Base material for strength verifications and welded steel structures.
Aluminium
Base material for strength verifications and welded aluminium structures.
Cast materials
Material group for strength verifications in accordance with the FKM guideline.
Locations
Niestetal
DEHead office: engineering, project management, 3D printing, metrology
- Lot size
- Prototypes to small series
- Materials
- Onyx, Nylon, glass fibre, Kevlar, carbon fibre, HSHT glass fibre, steel, aluminium, cast materials
- Markforged 3D printers (FDM)
- CAD systems (SolidWorks, Catia V5, Siemens NX, Creo)
- KISSsoft calculation tool
- FEM/MBS simulation tools
- Measurement data recorders (up to 8 channels)
- Access to partner manufacturing environments (including 5-axis milling machines)
Projects and components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Development/designEngineering | – | – | – | – | – |
| Calculation (KISSSOFT, gearbox/gear design)Engineering | – | – | – | – | – |
| Simulation (FEM, MBS)Engineering | – | – | – | – | – |
| Strength verification according to FKM guidelineEngineering | – | – | – | – | Steel, Aluminium, Cast materials, Welded steel structures, Welded aluminium structures |
| Metrology / measurement data recordingTesting | – | – | – | – | – |
| 3D printing (FDM build process) of thermoplastic functional models, prototypes and small seriesAdditive | – | – | – | – | Onyx (plastic), Nylon (plastic), Glass fibre, Kevlar, Carbon fibre, HSHT glass fibre |
| DocumentationEngineering | – | – | – | – | – |
| CommissioningAssembly | – | – | – | – | – |
| CE documentationEngineering | – | – | – | – | – |
| Project managementEngineering | – | – | – | – | – |
| QM consultingTesting | – | – | – | – | – |
| Drive technology (drive components, cycloid gearboxes)Engineering | – | – | – | – | – |
| Special gearbox constructionEngineering | – | – | – | – | – |
| Special machinery constructionEngineering | – | – | – | – | – |
| Test rig constructionEngineering | – | – | – | – | – |
| Automation technologyEngineering | – | – | – | – | – |
| Equipment designEngineering | – | – | – | – | – |
| Fixture designEngineering | – | – | – | – | – |
| Handling technologyEngineering | – | – | – | – | – |
| Prototype construction through to production readinessEngineering | – | – | – | – | – |
| ManufacturingMachining | – | – | – | – | – |
| Wire EDMMachining | – | – | – | – | – |
| Laser meltingAdditive | – | – | – | – | – |
| Direct digital manufacturingAdditive | – | – | – | – | – |
| Assembly and functional testingAssembly | – | – | – | – | – |
2 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 3D printer (FDM) | Markforged | – | – | – | iW Maschinenbau, Niestetal |
| 5-axis milling machines (used via partner/manufacturing interface) | – | – | – | – | – |
Additional services
Reference customers
Quality and certification
Quality assurance begins in the development stage, with QM consulting (initial sampling, test planning, audit preparation, process descriptions, among others with infra-Convert) and measurement data recording of up to eight mechanical quantities simultaneously. The company is certified to ISO 9001 by TÜV Nord and offers support with TÜV acceptance tests.
| Evidence | Niestetal |
|---|---|
| ISO 9001 |
History
- 1980
Founding of IW-Ideenschmiede
- 2002
Renamed iW Maschinenbau GmbH