Injection molding of thermoplastic and thermoset parts from 0.02 to 800 g, including toolmaking, finishing and assembly.
Kunststoffverarbeitung Bauer GmbH
01824 KönigsteinNew on Amplifa
About Kunststoffverarbeitung Bauer
Kunststoffverarbeitung Bauer GmbH in Königstein near Dresden manufactures technical plastic parts from thermoplastics and thermosets. On more than 33 injection molding machines (350–2500 kN), parts with weights from 0.02 g to 600 g are produced; in the thermoset sector, parts from 0.03 to 800 g are manufactured on 5 presses (600–1500 kN) and 7 injection molding machines (350–1800 kN). The value chain includes project planning and development, in-house toolmaking, injection molding, hybrid components through overmolding of metal, textile and electronic components, CNC machining, ultrasonic welding, pad printing, vacuum metallization, painting and module assembly. Lot sizes range from 50 pieces up to long-running products with up to 7 million parts per year in 3-shift operation. Customers come from industries such as mechanical engineering, power tools, medical technology, optics, automotive and fluid technology, including Bosch, Eppendorf, Siemens Healthineers, ABB and Rockwell Automation.
- Site
- Königstein
- Processes
- Thermoplastic injection molding, Thermoset pressing, Thermoset injection molding, Injection molding on vertical machines, Ejection of internal threads and undercuts using collapsible core technology, Production of hybrid components (overmolding of mesh fabrics, textile fibers, stamped, turned or, Module assembly (up to more than 20 individual components, semi-automated assembly workstations), Pad printing
- Materials
- PVDF (polyvinylidene fluoride), PSU (polyarylsulfones), PBT (polybutylene terephthalate), PPS (polyphenylene sulfide), PEEK (polyetheretherketone), PA6 GF35 (bearing flange), EP (epoxy resin), PVC
- Certificates
- ISO 9001, DIN ISO 50001, ISO 50001
- Founded
- 1991
- Industries
- Mechanical engineering, Fluid technology, Power tools, Medical technology, Optics, Automotive
- 01
Project planning
- 02
Design/project development
- 03
Toolmaking
- 04
Injection molding thermoplastic/thermoset
- 05
Hybrid components
- 06
Finishing (pad printing, metallization, painting)
- 07
CNC machining
- 08
Module assembly
- 09
Quality assurance
- 10
Delivery (own vehicle fleet)
Materials and Processes
Engineering thermoplastics (reinforced/unreinforced)
Processing of all engineering thermoplastics into injection molded parts from 0.02 to 600 g.
PEEK (polyetheretherketone)
High-temperature-resistant high-performance plastic with chemical resistance and sliding properties.
PPS (polyphenylene sulfide)
Very high chemical and heat deflection resistance, mostly as a compound with fillers.
PVDF (polyvinylidene fluoride)
Fluoropolymer with good thermal and chemical resistance, e.g. for pipe linings.
PSU (polyarylsulfones)
For service temperatures from −100 to 200 °C, high strength and chemical resistance.
PBT (polybutylene terephthalate)
Very good dimensional stability, low creep deformation and high abrasion resistance.
PF (phenolics)
Thermoset for e.g. plastic housings in electrical applications, economical molding compound.
EP (epoxy resin)
Thermoset with continuous service temperature up to 250 °C, good insulation and chemical resistance.
BMC (bulk molding compounds)
Thermoset with tooling-level dimensional accuracy and high temperature resistance, an alternative to aluminum die casting.
TPE (thermoplastic elastomers)
Among other things for overmolded stainless steel mesh as dust filters in power tools.
PA6 GF35
Glass-fiber-reinforced thermoplastic for mechanically stressed components such as bearing flanges.
Hybrid components (overmolding)
Overmolding of mesh fabrics, stamped, turned and milled parts as well as electronic components.
Sites
Königstein
DEHeadquarters, production, toolmaking, assembly
- Part weight / size
- 0.02–800 g
- Lot size
- from 50 pieces to 7 million parts/year
- Materials
- Thermoplastics, thermosets (PF, EP, BMC), hybrid components
- Over 33 injection molding machines 350–2500 kN (including Arburg)
- 5 thermoset presses 600–1500 kN
- 7 thermoset injection molding machines 350–1800 kN
- Vertical machines
- All-electric injection molding system with automation
- CNC milling and turning (toolmaking)
- Die sinking EDM
- 3D multisensor measuring systems
- Tactile 3D coordinate measuring machines
- Pad printing systems
- Ultrasonic welding
Reference Parts
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Thermoplastic injection moldingPlastics | – | – | 0.02 g – 600 g | 50 pieces – up to 7 million parts per year | Thermoplastics (reinforced and unreinforced), PVDF, PSU, PBT, PPS, PEEK |
| Thermoset pressingPlastics | – | – | 0.03 g – 800 g | – | Thermosets, PF phenolics, EP epoxy resin, BMC |
| Thermoset injection moldingPlastics | – | – | 0.03 g – 800 g | – | Thermosets, PF phenolics, EP epoxy resin, BMC |
| Injection molding on vertical machinesPlastics | – | – | – | – | Thermoplastics |
| Ejection of internal threads and undercuts using collapsible core technologyPlastics | – | – | – | – | Thermoplastics |
| Production of hybrid components (overmolding of mesh fabrics, textile fibers, stamped, turned orPlastics | – | – | – | – | Plastics with metal/textile/electronic components |
| Module assembly (up to more than 20 individual components, semi-automated assembly workstations)Assembly | – | – | – | – | Plastics (thermo and duro) |
| Pad printingSurface | – | – | – | – | Plastics |
| CNC turning and milling of plastic parts (subsequent machining)Machining | – | – | – | – | Plastics |
| Ultrasonic weldingJoining | – | – | – | – | Plastics |
| Vacuum metallization (EMC/ESD coating, solderable coating, reflective coatings)Surface | – | – | – | – | Plastics |
| Decorative plastic paintingSurface | – | – | – | – | Plastics |
| Toolmaking (new tools, revisions, modifications, maintenance, preform production)Engineering | – | – | – | – | Steel (tool steel) |
| CNC milling (toolmaking)Machining | – | – | – | – | – |
| CNC turning (toolmaking)Machining | – | – | – | – | – |
| Conventional milling and turning (toolmaking)Machining | – | – | – | – | – |
| Die sinking EDM (toolmaking)Machining | – | – | – | – | – |
| Welding (toolmaking)Joining | – | – | – | – | – |
| Thermoset deflashingSurface | – | – | – | – | Thermosets |
| 3D measurement optical/tactile, initial sample inspection reports according to VDA, SPCTesting | – | – | – | – | – |
13 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Injection molding machines | Arburg (among others) | over 33 | Clamping force 350 to 2500 kN | – | Königstein |
| Thermoset presses | – | 5 | 600 - 1500 kN | – | Königstein |
| Thermoset injection molding machines | – | 7 | 350 - 1800 kN | – | Königstein |
| Injection molding machine with automation, all-electric | Arburg | – | – | 2022 | Königstein |
| 3D measuring machine (optical-tactile) | – | – | – | 2019 | Königstein |
| Injection molding machine with special equipment for the smallest shot weights | – | – | – | 2019 | Königstein |
| CNC milling machines (toolmaking) | – | – | – | – | Königstein |
| CNC lathes (toolmaking) | – | – | – | – | Königstein |
| Grinding machine (toolmaking) | – | – | – | 2020 | Königstein |
| Pad printing systems | – | – | – | – | Königstein |
| 3D multisensor measuring systems (optical/tactile) | – | – | – | – | Königstein |
| Measuring microscopes | – | – | – | – | Königstein |
| Tactile 3D coordinate measuring machines | – | – | – | – | Königstein |
Additional services
Reference customers
Quality and Certification
Quality assurance is performed with 3D multisensor measuring systems (optical/tactile), measuring microscopes and tactile 3D coordinate measuring machines, including SPC monitoring and initial sample inspection reports according to VDA. All machines are monitored and documented live via the Arburg ALS MES system.
| Evidence | Königstein |
|---|---|
| ISO 9001 | |
| ISO 50001 |
Company History
- 1954
Founding of Karl-Hans-Bauer Kunststoffverarbeitung in Sulzbach-Laufen and of VEB Schaltelektronik Oppach in Königstein
- 1990
Start of cooperation
- 1991
Acquisition of the company and founding of Kunststoffverarbeitung Bauer GmbH
- 1995
Construction start at the site in the Leupoldishein industrial estate
- 1996
Move into the new buildings; start of the partnership with Bosch Power Tools
- 1997
Initial certification to DIN ISO 9001
- 2002
Separation from the sister company, expansion of toolmaking, start of preform production
- 2011
Expansion by 1900 m² of production and 400 m² of office space, start of terminal connection production
- 2013
Series production start of new ABB parts, acquisition of additional injection molding machines
- 2014
New corporate design and first trade fair appearances
- 2015
ERP system Wincarat, cooperation with Eppendorf, initial certification DIN ISO 50001, handover of management to Bettina Trinkner
- 2016
Sale of the partner company PET Sachsen GmbH & Co. KG
- 2018
Series production start of quench tube for UESA, additional injection molding machines, start of the Arburg ALS MES system
- 2019
Cooperation with Siemens Healthineers (epoxy resin tools), investment in a 3D measuring machine and a machine for the smallest shot weights
- 2020
Series production start of complex parts under 1 g for Rockwell Automation, grinding machine for toolmaking
- 2022
Additional Arburg injection molding machines including the first all-electric system with automation, toolmaking expansion