Toolmaking for particle foam: precision moulds made of aluminium for EPP, EPS, EPE, ETPU, PPE and EPA up to 5 × 3 × 2 m.
Schraml Metallverarbeitung GmbH & Co. KG
Waldershof, GermanyNew on Amplifa
Tools for particle foam from Waldershof
SCHRAML Metallverarbeitung manufactures in Waldershof tools and precision moulds for particle foams such as EPP, EPS, EPE, ETPU, PPE and EPA. The value chain – development, design, prototyping, toolmaking, production and quality inspection – remains in-house; only coatings are outsourced. The aluminium tools are produced in one piece in sizes up to 5 × 3 × 2 metres, which saves joining steps and maintains tolerances over the full component length. Around 50 employees accompany every tool from the drawing to series production, including series support as well as maintenance and repair of own and third-party tools. The company supplies industries such as automotive, heating & ventilation, logistics & packaging, sports & leisure, medical technology and aviation; as one of the first mould makers for particle foam, it produced a series tool for an aviation component. The company was founded in 1988 by Reinhold Schraml and has been run by Alexander Schraml, second generation, since 2015.
- Site
- Waldershof
- Processes
- Toolmaking for particle foam (moulds for EPP, EPS, EPE, ETPU, PPE, EPA), Design/CAD (tool concept, 3D model, chamber division, steam routing, ventilation), Prototyping (dimensional accuracy, density, demoulding), Milling, Drilling, Assembly, Maintenance and repair of foaming tools (own and third-party), Quality inspection
- Materials
- Aluminium, EPP, EPS, EPE, ETPU, PPE, EPA, EPP (particle foam)
- Certificates
- Internal quality inspection
- Founded
- 1988
- Employees
- around 50
- Industries
- Automotive, Heating & Ventilation, Logistics & Packaging, Sports & Leisure, Medical Technology, Aviation
- 01
Development
- 02
Design/CAD
- 03
Prototyping
- 04
Toolmaking (milling, drilling, assembly)
- 05
Quality inspection
- 06
Series support, maintenance and repair
Materials and foam types
Aluminium
Material for foaming tools, machined in sizes up to 5 × 3 × 2 m.
EPP (particle foam)
expanded polypropylene for dimensionally stable lightweight and damping components.
EPS (particle foam)
expanded polystyrene, among other things for packaging and insulation products.
EPE (particle foam)
expanded polyethylene for soft damping applications.
ETPU (particle foam)
expanded thermoplastic polyurethane, e.g. for elastic components.
PPE (particle foam)
particle foam based on polypropylene-polyethylene for special applications.
EPA (particle foam)
further particle foam type with its own process windows during foaming.
Locations
Waldershof
DEMain site: design, toolmaking, production, quality management
- Lot size
- One-off parts, prototypes, series
- Materials
- Aluminium; moulds for EPP, EPS, EPE, ETPU, PPE, EPA
- Five-axis machining centre MATEC 70HV
- Milling and drilling equipment
- Assembly and maintenance of foaming tools
Tools and components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Toolmaking for particle foam (moulds for EPP, EPS, EPE, ETPU, PPE, EPA)Toolmaking | – | 5 m × 3 m × 2 m | – | – | Aluminium |
| Design/CAD (tool concept, 3D model, chamber division, steam routing, ventilation)Engineering | – | – | – | – | – |
| Prototyping (dimensional accuracy, density, demoulding)Engineering | – | – | – | – | – |
| MillingMachining | – | – | – | – | Aluminium |
| DrillingMachining | – | – | – | – | Aluminium |
| AssemblyAssembly | – | – | – | – | – |
| Maintenance and repair of foaming tools (own and third-party)Assembly | – | – | – | – | – |
| Quality inspectionTesting | – | – | – | – | – |
Additional services
Quality
Every tool undergoes an internal quality inspection up to series readiness; dimensional accuracy, density and demoulding are checked, among other things, on the prototype.
| Evidence | Waldershof |
|---|---|
| Internal quality inspection |
History
- 1988
Founded by Reinhold Schraml in the basement of his home.
- 2015
Alexander Schraml takes over the company in the second generation.