Mold making and plastics technology: injection molding tools, injection molding production and engineering for medical technology, automotive and consumer goods.
Zechmayer GmbH Werkzeug- und Formenbau
GrafenwöhrNew on Amplifa
About Zechmayer
Zechmayer is a family-run company founded in 1966 and based in Grafenwöhr, uniting engineering, design, mold making and plastics technology under one roof. The company manufactures injection molding tools including prototypes, master molds and multi-component technology as well as plastic components from sampling through pre-series to series production. Tool manufacturing comprises 3- and 5-axis CNC and HSC milling, deep-hole drilling up to 1250 mm as well as sinker EDM and wire EDM; injection molding processes used include multi-component injection molding, MuCell® foaming, IMD, injection compression molding, PUR flooding and overmolding of aluminum decor, real wood veneer or carbon fiber. Standard thermoplastics, highly filled and high-temperature plastics, tool steel and aluminum are processed. Customers come from medical technology, automotive, consumer goods, household appliances and packaging industries. The headquarters in Grafenwöhr offers 3000 m² of production space and 1200 m² of office and social rooms; around 40 employees manufacture with a high degree of automation and in-house handling system construction.
- Site
- Grafenwöhr
- Processes
- Engineering (Moldflow analyses, DFM, DoE, FMEA), Design (CATIA, Creo, tool design), Mold making / toolmaking (prototypes, master molds, multi-component technology), 5-axis CNC milling (up to X: 2300 / Y: 1400 / Z: 900 mm), 3-axis HSC milling (up to X: 1400 / Y: 1000 / Z: 600 mm), 5-axis HSC milling (up to X: 1000 / Y: 1000 / Z: 600 mm), Deep-hole drilling (drilling depths up to 1250 mm, 4-side machining up to 1600 mm), Sinker EDM (up to X: 1500 / Y: 1000 / Z: 650 mm)
- Materials
- Standard thermoplastics, Highly filled materials (plastics), High-temperature plastics, Polyurethane (PUR), Aluminum (decor/inserts), Carbon fiber, Real wood veneer, Films (IMD)
- Certificates
- DIN EN ISO 9001, DIN EN ISO 14001, TISAX
- Founded
- 1966
- Employees
- 40
- Industries
- Medical technology, Automotive, Consumer goods, Household appliances industry, Packaging industry
- 01
Engineering (FMEA, Moldflow, DFM, DoE)
- 02
Design (CATIA, Creo)
- 03
Mold making (CNC/HSC milling, EDM, deep-hole drilling)
- 04
Sampling and pre-series
- 05
Injection molding series production
- 06
Inline quality control
- 07
Assembly and JIT delivery
Materials and Processes
CNC/HSC milling, 3- and 5-axis
Production of mold inserts and tools up to 2300 × 1400 × 900 mm, also as contract manufacturing for individual parts and series.
Deep-hole drilling
Drilling depths up to 1250 mm and 4-side machining up to 1600 mm for cooling channels and mold cavities in toolmaking.
Sinker EDM and wire EDM
Production of precise contours and tightest tolerances in mold making.
Multi-component injection molding
Tools for rotary tables, turntable plates, index plates, sliding tables and transfer technology for process substitution.
MuCell® foaming
Physical foaming for weight reduction and increased molded part stability at lower clamping force.
In-Mold-Decoration (IMD)
Single-sheet and reel-to-reel technology with functional integration for refined plastic surfaces.
PUR flooding
High-gloss polyurethane surface protection, chemical-resistant, UV-resistant, self-healing and scratch-resistant.
Overmolding
Insertion of aluminum decor, real wood veneers, carbon fiber, synthetics and films for design components.
Injection compression molding and variotherm
Surface design with laser structures, chrome components and design decor.
Tolerance classes TG1–TG3
Manufacture of demanding tolerances with metal part inserts and high-temperature plastics.
Sites
Grafenwöhr
DEHeadquarters, mold making and plastics technology production
- Lot size
- Individual parts, prototypes, small series, series
- Materials
- Standard thermoplastics, highly filled plastics, high-temperature plastics, PUR, tool steel, aluminum, carbon fiber
- 5-axis CNC milling machine (X: 2300 / Y: 1400 / Z: 900 mm)
- 3-axis HSC milling machine (X: 1400 / Y: 1000 / Z: 600 mm)
- 5-axis HSC milling machine (X: 1000 / Y: 1000 / Z: 600 mm)
- Deep-hole drilling machine (drilling depths up to 1250 mm)
- Sinker EDM machine (X: 1500 / Y: 1000 / Z: 650 mm)
- Wire EDM machine (X: 750 / Y: 500 / Z: 400 mm)
- Injection molding machines incl. multi-component, MuCell®, IMD, PUR, injection compression molding
- Dry-air drying system with closed material circuit
- In-house handling robot system
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Engineering (Moldflow analyses, DFM, DoE, FMEA)Engineering | – | – | – | – | – |
| Design (CATIA, Creo, tool design)Engineering | – | – | – | – | – |
| Mold making / toolmaking (prototypes, master molds, multi-component technology)Engineering | – | – | – | – | Steel, Aluminum |
| 5-axis CNC milling (up to X: 2300 / Y: 1400 / Z: 900 mm)Machining | – | 2300 mm × 1400 mm × 900 mm | – | Individual parts – Series | Steel, Aluminum, Plastic |
| 3-axis HSC milling (up to X: 1400 / Y: 1000 / Z: 600 mm)Machining | – | 1400 mm × 1000 mm × 600 mm | – | – | Steel, Aluminum |
| 5-axis HSC milling (up to X: 1000 / Y: 1000 / Z: 600 mm)Machining | – | 1000 mm × 1000 mm × 600 mm | – | – | Steel, Aluminum |
| Deep-hole drilling (drilling depths up to 1250 mm, 4-side machining up to 1600 mm)Machining | – | 1600 mm | – | – | Steel |
| Sinker EDM (up to X: 1500 / Y: 1000 / Z: 650 mm)Machining | – | 1500 mm × 1000 mm × 650 mm | – | – | Steel |
| Wire EDM (up to X: 750 / Y: 500 / Z: 400 mm)Machining | – | 750 mm × 500 mm × 400 mm | – | – | Steel |
| Contract manufacturing (individual parts, prototypes, small series, series)Machining | – | – | – | Individual parts – Series | – |
| Tool repair and modification service (incl. third-party tools, 24/7 emergency service)Engineering | – | – | – | – | – |
| Injection molding / plastics technology (series production, high degree of automation)Plastics | Tolerance classes TG1 - TG3 | – | – | Sampling – Series | Standard thermoplastics, highly filled materials, high-temperature plastics |
| Sampling / pre-series production of in-house and third-party toolsPlastics | – | – | – | Sampling – Pre-series | – |
| Multi-component injection molding (rotary table, turntable plate, index plate, sliding table,Plastics | – | – | – | – | Plastic |
| MuCell® foaming / physical foamingPlastics | – | – | – | – | Plastic |
| Gas counter-pressure processPlastics | – | – | – | – | Plastic |
| Chemical foaming processesPlastics | – | – | – | – | Plastic |
| IMD (In-Mold-Decoration: single-sheet technology, reel-to-reel technology, functional integration)Plastics | – | – | – | – | Plastic, Films |
| PUR flooding / polyurethane coating (one-shot, two-shot, mold in color)Surface | – | – | – | – | Polyurethane |
| Overmolding of aluminum decor, real wood veneers, carbon fiber, synthetics, filmsPlastics | – | – | – | – | Aluminum, Real wood veneer, Carbon fiber, Synthetics, Films |
| Injection compression moldingPlastics | – | – | – | – | Plastic |
| Variotherm applicationsPlastics | – | – | – | – | Plastic |
| Laser structures / chrome components / design decorSurface | – | – | – | – | Plastic |
| Metal insert injection molding (insert molding)Plastics | Tolerance classes TG1 - TG3 | – | – | – | Metal, Plastic |
| Component measurement and statistical process analysis, inline/end-of-line testsTesting | – | – | – | – | – |
| Incoming goods inspections of raw materials and semi-finished productsTesting | – | – | – | – | – |
9 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 5-axis CNC milling machine | – | – | X: 2300 / Y: 1400 / Z: 900 mm | – | Grafenwöhr |
| 3-axis HSC milling machine | – | – | X: 1400 / Y: 1000 / Z: 600 mm | – | Grafenwöhr |
| 5-axis HSC milling machine | – | – | X: 1000 / Y: 1000 / Z: 600 mm | – | Grafenwöhr |
| Deep-hole drilling machine | – | – | Drilling depths up to 1250 mm, 4-side machining up to 1600 mm | – | Grafenwöhr |
| Sinker EDM machine | – | – | X: 1500 / Y: 1000 / Z: 650 mm | – | Grafenwöhr |
| Wire EDM machine | – | – | X: 750 / Y: 500 / Z: 400 mm | – | Grafenwöhr |
| Injection molding machine (multi-component, MuCell®, IMD, PUR, injection compression molding) | – | – | – | – | Grafenwöhr |
| Dry-air drying system (low dew point, closed material circuit) | – | – | – | – | Grafenwöhr |
| In-house handling robot system (in-house handling system construction) | – | – | – | – | Grafenwöhr |
Additional services
Quality
Engineering, mold making and plastics technology work in a closed, certified system with a lived zero-defect culture. This includes component measurement and statistical process analysis, incoming goods inspections, inline and end-of-line tests, shopfloor audits as well as continuous improvement following the 8D methodology.
| Evidence | Grafenwöhr |
|---|---|
| DIN EN ISO 9001 | |
| DIN EN ISO 14001 | |
| TISAX |
History
- 1966
Start as a full-service partner in mold making and plastics technology