Technology & Development

Concept Phase

During the concept phase, our engineers work closely with you from the outset to accurately identify requirements and develop measures that prevent delays and avoid additional costs later on. Through specification reviews, creative brainstorming and thorough feasibility studies, we develop a solution that optimally combines functionality, installation space, sealing performance, service life and manufacturability.

Whether it’s a completely new design or a targeted modification of a tried-and-tested geometry, we work closely with you to develop the right sealing solution that saves time and effort and keeps you moving forward reliably.

Development Phase

During the development phase, we create bespoke sealing solutions which we test virtually using 3D models and simulations, such as finite element methods (FEM) or motion analyses, in order to validate functionality at an early stage and accelerate the transition to series production.
For complex components, we also rely on physical prototypes produced by machining or 3D printing to test geometries in real-world conditions and optimise them iteratively.

With the support of our materials experts and a state-of-the-art compounding laboratory, we develop customised compounds, evaluate alternatives and use design and process FMEA to eliminate potential sources of failure at an early stage. In this way, we bring your sealing solution efficiently and reliably to production-ready status.

Implementation Phase

During the implementation phase, we recommend using near-series prototypes where the schedule permits. These are manufactured using tooling concepts that closely resemble those used in subsequent production, thereby enabling a realistic assessment. The compound used is already production-ready, which means that valuable insights into process parameters can be gained at this stage.
Based on these results, the essential foundations for efficient, high-quality mass production are laid here.

Qualification Phase

During the qualification phase, both prototypes and first articles from production tools undergo extensive testing in our fully equipped laboratory. The scope of testing, defined in consultation with you, covers physical properties, geometry, tolerances and durability – documented in first-article inspection reports that comply with relevant standards (e.g. VDA or IATF 16949). Using a structured Advanced Product Quality Planning (APQP) process, we ensure a stable production process and assist you with functional testing, as well as with commissioning specialised testing from external institutes, to reliably meet even the most complex requirements.

Production Ramp-up phase

During the production ramp-up phase, we ensure stable processes with high process capability through consistent monitoring and the use of the SPC method. Cpk and PPK values demonstrate both short-term and long-term capability. Our goal is zero-defect quality: where necessary, we carry out 100% inspections, ranging from opto-electronic sorting to manual visual inspection, to keep ppm rates as low as possible.
In addition, random inspections in accordance with ISO 2859, documentation throughout the production process and a barcode-based traceability system ensure maximum transparency and quality – from the mix to the finished component.