Bisher übliche Verfahren zur Verbundteilherstellung

1. Reel-to-Reel

With the Reel-to-Reel-Process, the manufacturing process is split into single processes. The pre-cut resp. overmoulded metal band is buffer-stored on reels.

The disadvantages are inter alia:

Long order processing times due to the 2-3 separate processes

High reject risks, since a large number of parts, is buffer-stored in semi-finished condition – defects can only be detected after the last machining process

High potential material losses due to separate pilot stamping processes

Risk of part deformation through repeated winding and unwinding of the bands

2. „In-Line“

With the "in-line" method, the stamping machines for die-cutting and finishing work work in line with the injection moulding machine. The slower injection process is compensated both by multiple tools and band-loops between the machines. The thicker the metal band, the greater the distance between the machines has to be.

The main disadvantages are:

Extremely high floor space requirements due to the 3 inter-connected machines

High material losses caused by the loops, e.g. in case of faults or the production start

Risk of parts deformation by loop operation

High investment costs as three machines are required for the production process