• Comprehensive device assembly: from component assembly to printing

    Comprehensive device assembly: from component assembly 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 manufacture your assemblies and devices: Assembly at Plastro Mayer

Plastro Mayer handles your entire device assembly process—from the initial idea to packaging. Since 1987, we have been combining injection molding, the associated toolmaking, and professional device or assembly mounting under one roof.

This is because devices often consist of various elements such as sockets, screws, individual injection-molded parts, and cables. Plastro Mayer can easily handle the complete assembly of all elements. We not only assemble complete devices, but also offer assembly of individual parts, which you can use for further processing as you wish. 

Our device assembly involves several steps:

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

•    Equipment: If necessary, the parts from plastic production are supplemented with elements such as associated cables. If these 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 necessary components, are joined together using processes such as plastic bonding and ultrasonic welding. Whether individual assemblies or complete devices.

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

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

Whether it's a component or complete assembly, we'll make your project a reality.

The assembly of complete devices and assemblies by us as the manufacturer offers you comprehensive convenience. Thanks to our precise knowledge of the specific properties and requirements of the individual parts, Plastro Mayer can guarantee the precise and high-quality assembly of plastic parts. 

Why choose Plastro Mayer as your full-service provider?

Plastro Mayer combines all production steps under one roof. This brings you measurable advantages: 

Quality advantages:

  • Expertise in every component we manufacture ourselves
  • Direct coordination between production and assembly
  • Continuous quality control without interfaces

Cost savings:

  • Eliminated transport costs between different locations
  • Reduced logistics and coordination costs
  • Shorter production times thanks to optimized processes

Complete solution:

  • In-house cable production for complete electrical appliances
  • Direct component coordination between all areas
  • One contact person for all project phases

We always work with precision and prioritize customer satisfaction and quality—see for yourself!

What joining methods does Plastro Mayer use for assembly?

During assembly, your manufactured injection molded parts are joined together using special processes. These processes differ in terms of 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 again. Non-detachable processes for joining plastics include: 

Bonding: Special adhesives are used to join the elements together. Each adhesive has specific properties that make it suitable for certain plastics. Choosing the right adhesive ensures a resilient construction.

Riveting: 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 purposes.

Welding: At Plastro Mayer, we use various welding processes for assembly. 

What welding processes does Plastro Mayer use?

  • Ultrasonic welding: High-frequency sound waves (20-70 kHz) fuse plastics together using frictional heat. Ideal for precise, fast connections without additives.
  • Heating element welding/mirror welding: A heated metal tool melts the contact surfaces. After removing the heating element, the parts are permanently joined under pressure.
  • Hot gas welding (by convection): Heated air melts hard-to-reach areas. Particularly flexible for complex geometries and subsequent repairs.

Our capabilities in device and component assembly

Do you have a custom project? We are also happy to fulfill requests with special requirements. Thanks to our in-house toolmaking, in-house assembly, and established partnerships with external suppliers, we are able to respond to your individual ideas. 

 

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 Equipment
Do you have a complete device or assembly and want components and assembly from a single source? Then you've come to the right place! Our experts will be happy to help you and prepare a customized quote for you. Simply send us your inquiry, specifying 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 contact you for further information. Get in touch now and receive personal advice from our experts, who are here to assist you – we look forward to your inquiry!

FAQ's

What is component assembly or device assembly?
Assembly combines at least two individual parts to form functional intermediate products. An assembly can consist purely of plastic parts or also contain 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 composed of individual assemblies.
What happens to the finished device after it has been completely assembled?
After the device has been assembled, we ensure that the quality and functionality of your product is guaranteed. We then package your finished product in our sales packaging or in your preferred packaging and ship your order in accordance with safety regulations. Temporary storage at our facility in Trochtelfingen is also possible.
What welding processes are used in equipment assembly at Plastro Mayer?
In our assembly and device assembly, we use three different welding processes to achieve the ideal result for each individual customer project. These include ultrasonic welding, heating element 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 device assembly?
We print on plastic parts using pad printing, among other methods, which allows even multicolored graphics to be printed on irregular surfaces. This involves placing a silicone rubber pad on the plastic element. The print quality is high, and the method is particularly well suited to all types of plastic. Find out more about our other printing processes in injection molding post-processing, such as painting and hot stamping.
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