Toolmaking and injection moulding: plastic parts from under 1 g to 700 g, from design to series production
Werner Dübi AG
Grossaffoltern (CH)New on Amplifa
Expertise from idea to series production
Werner Dübi AG is a family-owned company in Grossaffoltern (canton of Bern) that manufactures injection-moulded parts and the corresponding injection moulds in-house. The value chain covers consulting, development and design using CAD and fill simulation, prototyping, toolmaking and injection moulding production on 20 machines with clamping forces from 150 to 3500 kN. All common thermoplastics are moulded, from PS and PP through to high-performance engineering plastics such as PEEK; part weights range from under 1 g for micro and very small parts up to 700 g, and components such as overmoulded screws are possible up to 0.5 m in length. Specialities include 2-component parts, vertical injection moulding with insert loading and the overmoulding of components such as stators and electronic parts. In addition, the company offers ultrasonic welding, laser welding, assembly of modules and finishing as contract services. The parts go to customers from engine technology, the construction industry, electrical engineering, the fertiliser and consumer goods sectors and are installed in end products worldwide.
- Site
- Grossaffoltern
- Processes
- Injection moulding (plastic injection moulding), Overmoulding of parts (e.g. stator, electronic components, screw 0.5 m), 2-component injection moulding (2K, 2 injection units), Toolmaking / mould making (design through to series tooling), CNC milling, HSC hard milling, CNC turning, Wire EDM (wire cutting)
- Materials
- PS, PP, PE, PC, PMMA, ABS, POM, PA
- Certificates
- ISO 9001:2015
- Industries
- Automotive industry, Medical technology, Healthcare and pharmaceuticals, Apparatus and mechanical engineering, Electronics and electrical industry, Consumer goods and building supplies industry
- 01
Consulting
- 02
Development and design (CAD, fill simulation)
- 03
Prototyping
- 04
Toolmaking (CNC milling, EDM, grinding)
- 05
Injection moulding 1–700 g
- 06
Post-processing: ultrasonic welding, laser welding, finishing
- 07
Quality inspection
Locations
Grossaffoltern
CHHead office with toolmaking, design and injection moulding production
- Part weight / size
- Injection-moulded parts under 1 g to 700 g; overmoulded
- Lot size
- Small series to large series
- Materials
- Thermoplastics (PS, PP, PE, PC, PMMA, ABS, POM, PA, PBT, PET, PPS, PSU, PEI, PEEK, TPE, TPU, PPA, PPO)
- 20 injection moulding machines (Arburg, Engel, Netstal), 150–3500 kN, including Arburg 275V vertical machine and Arburg 420V 2K with two injection units
- Fehlmann Picomax 56 Top, Maho MH 400, Mikron HSM 700 and further milling and machining centres
- Lathes from Schaublin, EMCO, Rima and Cincom C16 bar loader
- Wire EDM machines Agie Charmilles Cut 200 SP and Fanuc Robocut α-1c
- Sinker EDM machines Agie Charmilles FO 350S (48-tool changer), 350 µ, Charmilles Roboform 200
- Surface, cylindrical and jig grinding machines (Blohm, Tacchella, Kellenberger, Schaublin, Hauser)
- 3 Iepco Peenmatic micro shot blasting systems
- Telsonic USP750 ultrasonic welding machine
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Injection moulding (plastic injection moulding)Plastics | – | – | less than 1 g – 700 g | Small series – Large series | PS, PP, PE, PC, PMMA, ABS, POM, PA, PBT, PET, PPS, PSU, PEI, PEEK, TPE, TPU, PPA, PPO |
| Overmoulding of parts (e.g. stator, electronic components, screw 0.5 m)Plastics | – | 0.5 m | 1 g – 700 g | – | thermoplastics |
| 2-component injection moulding (2K, 2 injection units)Plastics | – | – | 700 g | – | thermoplastics |
| Toolmaking / mould making (design through to series tooling)Engineering | – | – | – | – | – |
| CNC millingMachining | – | – | – | – | – |
| HSC hard millingMachining | – | – | – | – | – |
| CNC turningMachining | – | – | – | – | – |
| Wire EDM (wire cutting)Machining | – | – | – | – | – |
| Sinker EDMMachining | – | – | – | – | – |
| Electrical discharge machining, sinker EDM with 48-tool changerMachining | – | – | – | – | – |
| Grinding (jig, surface, internal and external cylindrical grinding)Machining | – | – | – | – | – |
| HoningMachining | – | – | – | – | – |
| PolishingSurface treatment | – | – | – | – | – |
| Micro shot blasting (surface finishing)Surface treatment | – | – | – | – | – |
| EngravingSurface treatment | – | – | – | – | – |
| Hardening of small partsHeat treatment | – | – | – | – | – |
| Ultrasonic weldingJoining | – | 370 mm | – | – | Plastics |
| Laser welding (contract work)Joining | – | – | – | – | – |
| Module assembly / post-processingAssembly | – | – | – | – | – |
| Prototyping / prototype sourcingEngineering | – | – | – | – | Plastics |
| Design / development using CAD technology and fill simulationEngineering | – | – | – | – | – |
| Finishing (contract service)Surface treatment | – | – | – | – | – |
49 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Injection moulding machine | Arburg 170 18 t (moulding in parting line) | 1 | 18 t clamping force | – | Grossaffoltern |
| Injection moulding machine | Arburg 170 18 t (pick-and-place) | 1 | 18 t clamping force | – | Grossaffoltern |
| Injection moulding machine | Arburg 220S 250-60 | 1 | 25 t | – | Grossaffoltern |
| Injection moulding machine | Arburg 270C 400-70 (handling) | 3 | 40 t | – | Grossaffoltern |
| Injection moulding machine | Arburg 270C 400-100 | 1 | 40 t | – | Grossaffoltern |
| Injection moulding machine (vertical, insert loading) | Arburg 275V | 1 | – | – | Grossaffoltern |
| Injection moulding machine | Arburg 370H 850-210 (gating picker) | 1 | 85 t | – | Grossaffoltern |
| Injection moulding machine | Arburg 420S 800-350 (handling) | 1 | 80 t | – | Grossaffoltern |
| Injection moulding machine | Arburg 420C 1000-350 (handling) | 1 | 100 t | – | Grossaffoltern |
| Injection moulding machine | Arburg 420C 1000-290 (handling) | 1 | 100 t | – | Grossaffoltern |
| Injection moulding machine | Arburg 420C 1000-290 | 1 | 100 t | – | Grossaffoltern |
| Injection moulding machine 2K | Arburg 420V 1000-350/60, 2 injection units | 1 | 100 t | – | Grossaffoltern |
| Injection moulding machine | Arburg 520C 2000-800 | 1 | 200 t | – | Grossaffoltern |
| Injection moulding machine | Arburg 520C 2000-650 | 1 | 200 t | – | Grossaffoltern |
| Injection moulding machine | Engel ES330/125 HL | 1 | 125 t | – | Grossaffoltern |
| Injection moulding machine | Engel ES600/145 | 1 | 145 t | – | Grossaffoltern |
| Injection moulding machine | Netstal HP3500-1650 (handling) | 1 | 350 t | – | Grossaffoltern |
| Ultrasonic welding machine | Telsonic USP750 | 1 | Working area W×D 370×250 mm, welding force 600 N | – | Grossaffoltern |
| Milling machine | Fehlmann Picomax 56 Top, additional C-axis | 1 | – | – | Grossaffoltern |
| Milling machine | Maho MH 400 | 1 | – | – | Grossaffoltern |
| Milling machine (HSC) | Mikron HSM 700 | 1 | – | – | Grossaffoltern |
| Milling machine | Mikron WF51C | 1 | – | – | Grossaffoltern |
| Milling machine | Mikron WF31C | 1 | – | – | Grossaffoltern |
| Milling machine | Mikron WF3S | 1 | – | – | Grossaffoltern |
| Milling machine | Mikron WF 3DCM | 1 | – | – | Grossaffoltern |
| Machining centre | Mikron VC 1000 | 1 | – | – | Grossaffoltern |
| Drilling machine / hole drilling automaton | Fanuc Tape drill Mate | 1 | – | – | Grossaffoltern |
| Lathe | Schaublin 102 | 1 | – | – | Grossaffoltern |
| Lathe | EMCO turn 342 | 1 | – | – | Grossaffoltern |
| Lathe | Rima Turn TC-1840 | 1 | – | – | Grossaffoltern |
| Lathe | Schaublin 125CCN | 1 | – | – | Grossaffoltern |
| Turning automaton | Star (Cincom) C16, bar loader | 1 | – | – | Grossaffoltern |
| Start-hole drilling machine | Charmilles SH 2 | 1 | – | – | Grossaffoltern |
| Wire EDM machine | Agie Charmilles Cut 200 SP | 1 | – | – | Grossaffoltern |
| Wire EDM machine | Fanuc Robocut α-1c | 1 | – | – | Grossaffoltern |
| Micro shot blasting system | Iepco Peenmatic | 3 | – | – | Grossaffoltern |
| Surface grinding machine | Jakobsen 824 | 1 | – | – | Grossaffoltern |
| Surface grinding machine | Jakobsen | 1 | – | – | Grossaffoltern |
| Surface grinding machine | Blohm Planomat | 1 | – | – | Grossaffoltern |
| Surface grinding machine | Tacchella 40L | 1 | – | – | Grossaffoltern |
| Cylindrical grinding machine | Kellenberger 600U | 1 | – | – | Grossaffoltern |
| Cylindrical grinding machine | Schaublin 102 | 2 | – | – | Grossaffoltern |
| Thread electrode lathe / electrode lathe | Schaublin 102 CNC | 1 | – | – | Grossaffoltern |
| Sinker EDM machine | Agie Charmilles FO 350S, 48-tool changer | 1 | – | – | Grossaffoltern |
| Sinker EDM machine | Agie Charmilles 350 µ | 1 | – | – | Grossaffoltern |
| Sinker EDM machine | Charmilles Roboform 200 | 1 | – | – | Grossaffoltern |
| Sinker EDM measuring system | – | 1 | – | – | Grossaffoltern |
| EDM pre-setting device | Erowa PreSet 2D | 1 | – | – | Grossaffoltern |
| Jig grinding machine | Hauser 3 SMO | 1 | – | – | Grossaffoltern |
Additional services
Reference customers
Quality
Werner Dübi AG has been ISO 9001 certified since 2004 (SGS, certificate CH04/0669); the management system covers plastics processing and production of plastic parts. Quality inspection is staffed with dedicated personnel and accompanies production from mould manufacture to the finished component.
| Evidence | Grossaffoltern |
|---|---|
| ISO 9001:2015 |
History
- 2004
Initial certification of the management system to ISO 9001 by SGS on 07.10.2004.
- 2025
Recertification to ISO 9001:2015 (certificate CH04/0669, issue 9, valid until 06.10.2028).