• Comprehensive device assembly: from mounting to printing

    Comprehensive device assembly: from mounting to printing

What we offer ...

Assembly

Assembly

We offer everything from simple assemblies to complete devices. Injection molded parts and supply cables from our own production, as well as required purchased parts can be assembled into complete, ready-to-use devices for you.
Further processing by joining

Further processing by joining

Ultrasonic welding, hot plate welding / mirror welding, hot gas welding, laser welding in toolmaking, bonding, screw connections, brass inserts for hot insertion and riveting.
Coating by printing process

Coating by printing process

Pad printing process (single or two-component process with multiple colors) and hot stamping
Packing

Packing

On request, your ordered goods can be dispatched directly in your individual sales packaging. Otherwise, we will deliver your order in our own packaging.
External partners

External partners

In cooperation with external partners, we offer the coating steps vapor deposition, electroplating and painting with further processing at our company.
Safety checks

Safety checks

We carry out all the necessary safety checks in the company to ensure that the safety standards are met and that you receive a high-quality product.

We produce your assemblies and devices: Assembly at Plastro Mayer

Your project starts with your idea - and we realise it. Our injection moulding and associated toolmaking departments are not the only facilities available to you: We also complete the order professionally and expertly in our device assembly department. Devices often consist of various elements such as bushings, screws, injection moulded parts and cables. Complete assembly of all elements is no problem at Plastro Mayer. We not only assemble complete appliances, but also individual assemblies that you can use for further processing as required. 

 

Our appliance assembly comprises several steps:

•    Post-processing: : After the injection moulded parts have been produced, they are post-processed to achieve an ideal result. Printing and grinding techniques are used for this, for example.

•    Equipment: If necessary, the plastic parts produced by injection moulding are supplemented by elements such as associated cables. If these elements are not also manufactured by us, they are provided by you or by external partners.

•    Assembly process: Your plastic parts, as well as all other required components, are joined together using processes such as plastic bonding and ultrasonic welding.

•    Packaging: Last but not least, we make sure that the products are packaged professionally. On request, we can also dispatch the items directly in your desired sales packaging.  

Do you have any questions or a specific request for your next project? Get in touch with us and we will be happy to help you.  

Whether subassembly or complete assembly - Plastro Mayer realises your project

The assembly of complete appliances and assemblies by us as a manufacturer offers you comprehensive convenience. Thanks to our precise knowledge of the specific properties and requirements of the individual parts, Plastro Mayer can guarantee precise and high-quality assembly of the plastic parts. Complete assembly on site not only leads to optimum quality assurance, but also to cost savings, as additional transport costs are eliminated. Production is also more efficient as no time is lost transporting the parts to a separate assembly facility. 
If you still require individual parts such as cables and wires for the complete assembly of your electrical appliances, we can produce these ourselves. As your complete manufacturer, this enables us to ensure that all components always meet your exact project specifications and that the end product fulfils your desired performance requirements. We work with precision and prioritise customer satisfaction and quality - see for yourself!

Technical connection by joining: Plastic bonding, welding or riveting

During assembly, your injection moulded parts are joined together using special processes. These processes differ in their detachability depending on the requirements of the project. A detachable connection can be created using screws, for example, so that the individual parts can be separated from each other again. Non-detachable processes for joining plastic include: 

Gluing: Special adhesives are used to bond the elements together. Each adhesive has specific properties that make it suitable for certain plastics. The right choice can ensure a resilient construction.

Welding: At Plastro Mayer, we use various methods for assembly. These are:

  • Ultrasonic welding: High-frequency sound waves (typically in the range of 20 kHz to 70 kHz) are used to vibrate the molecules in the plastic parts to be joined. These vibrations generate frictional heat at the contact surfaces of the materials, causing the plastics to melt and form a strong bond.
  • Hot plate welding/mirror welding: The plastic elements to be joined are heated by a heated metal tool known as a heating element or mirror. Once the contact surfaces of the plastics are sufficiently soft or melted, the heating element is removed and the melted surfaces are joined together under pressure to form a permanent bond.
  • Hot gas welding (by convection): A gas, usually simple air, is heated to a high temperature and blown through a nozzle onto the plastic surfaces to be joined. The heated air melts the surfaces of the plastics. These can then be permanently joined together under pressure to create a strong bond. The advantage of this process is that even hard-to-reach areas can be welded.

Rivets: In this mechanical joining process, rivets are inserted into the plastic parts to be joined, creating a secure connection. Riveting is a flexible process and is used, among other things, to fasten assemblies or for decorative requirements.

 

Our capabilities in device and component assembly

Do you have a customised project? We are also happy to realise requests with special wishes. Thanks to our own toolmaking facilities, in-house assembly and our established partnerships with external suppliers, we are able to cater to your individual requirements.

 

Complete assembly

Plastro Mayer's appliance construction services include complete assembly, in which all individually manufactured components or assemblies are joined together to form a complete appliance. We use our many years of expertise in assembly to ensure that all processes run smoothly and a high-quality result is achieved. As we also manufacture all the devices for assembly ourselves, we can work flexibly. 

  • Mockmill

    Mockmill

    Mill made of bio-based plastic, complete assembly inhouse
  • Wet dry vacuum cleaner

    Wet dry vacuum cleaner

  • Assembly of components

    Assembly of components

Printing

Appearance and quality have a lasting impact on the impression and value of a product. Accordingly, we not only manufacture your components to be functional, but also visually appealing. At Plastro Mayer, we add the final touch with a variety of finishing methods in the form of painting, coating, printing and hot stamping.

  • Switch button

    Switch button

    3-color printing
  • hand dryer hood

    hand dryer hood

  • Multiple socket EM

    Multiple socket EM

    3x 2-color priniting, Swiss multiple socket EM version
  • Aperture

    Aperture

    4-color printing
  • Accessory cover

    Accessory cover

    silver print
  • Cordless clipper

    Cordless clipper

    impact resistant, with pad printing, ultrasonic welded thread inserts

Module assembly

In module assembly, several individual parts are assembled into a finished module by means of various assembly steps. These assemblies can then either be used as stand-alone products or integrated into more complex systems. Assembly can be both manual and (partially) authorised and includes various joining processes such as welding, gluing and riveting.

  • Water drain

    Water drain

  • Oil separator

    Oil separator

  • Control valve

    Control valve

  • Industrial vacuum cleaner

    Industrial vacuum cleaner

  • Battery broom

    Battery broom

  • Steam pressure hose

    Steam pressure hose

Contact our injection moulding and assembly experts now

Device assembly

Juergen Hack

Sales manager injection molding and devices
Do you have a complete appliance or an assembly and want components and installation from a single source? Then you've come to the right place! Our experts will be happy to help you and prepare a customised quotation for you. Simply send us your enquiry, stating the corresponding annual quantity and the required purchased parts, using our contact form. If available, please use the attachment for drawings and 3D data in STEP or IGES format. We will then get in touch with you for further information. Get in touch now and receive personalised advice from our experts who will be happy to assist you - we look forward to receiving your enquiry!

FAQ's

What is component assembly or device assembly?
Component assembly is the assembly of individual components into intermediate products, so-called assemblies, which consist of various individual parts (at least two) and together form a functional unit. It can consist purely of plastic parts or also include other components such as electrical accessories, cables, screws and rivets. Device assembly, on the other hand, involves putting together complete and functional devices, which in turn are often made up of individual assemblies.
What happens to the finished appliance after assembly?
Once the device has been assembled, we ensure that the quality and functionality of your product is guaranteed. We then pack your finished product in our or your desired sales packaging and dispatch your order safely. Interim storage at our premises in Trochtelfingen is also possible.
Which welding processes are used in appliance assembly at Plastro Mayer?
We use three different welding processes in our component and appliance assembly to achieve the ideal result for each individual customer project. These include ultrasonic welding, hot plate welding or mirror welding and hot gas welding. The appropriate process is selected depending on the requirements of the project or the individual plastic elements.
How does the pad printing process work in appliance assembly?
Wir bedrucken Kunststoffteile unter anderem mittels des Tampondrucks, wodurch selbst mehrfarbige Grafiken auf unregelmäßigen Flächen gedruckt werden können. Dabei wird ein Tampon aus Silikonkautschuk auf das Kunststoffelement platziert. Die Druckqualität ist hoch, und die Methode lässt sich besonders gut auf Kunststoff jeder Art anwenden. Informieren Sie sich auch über unsere weiteren Druckverfahren in der Spritzguss-Nachbearbeitung wie Lackieren und Heißprägen.
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