Business Area Assembly | Plastro Mayer GmbH

Assembly

Assembly

What we offer ...

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

Ultrasonic welding (by friction), hot plate welding / mirror welding (by heat conduction), hot gas welding (by convection), laser welding in tooling (by radiation), bonding, bolted joints, brass insert for hot insertion and riveting.

Coating by printing process

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

Packing

We are happy to deliver in our packaging or directly in their retail packaging.

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

We carry out any necessary safety checks on our premises.

Assembly in the plastics industry ...

Most devices consist not only of one plastic part, but of several components such as bushings, screws, injection-molded parts, cables... From simple assemblies to complete devices, everything can be assembled. An assembly consists of at least two products that are connected together. Most devices consist of several injection molded parts, cables, motor and other purchased parts. There are various methods for joining the parts together, such as welding, gluing, riveting, etc.

An excerpt of our capabilities ...

Get in touch with our experts ...

Device assembly

You have a complete device or an assembly and do not want different suppliers for it? Then you have come to the right place! Our experts will be happy to help you and create your individual offer for your assembly. To do this, simply send us your inquiry with details of the corresponding annual quantity and the required purchased parts using our contact form. Please attach drawings as well as 3D data in TEP or IGES format, if available. Our expert will then contact you for further information.

FAQ's

Assembly

What welding processes can you use in equipment assembly?

We use 3 different welding processes in our subassembly and equipment assembly. Most frequently, we use ultrasonic welding. In this process, components made of thermoplastic materials are welded together. Ultrasonic waves with frequencies from 15 up to 70 kHz are used in this process. The vibrations are introduced into the plastic part by sonotrodes. The components are joined together by fusion, which occurs as a result of friction, and are joined together with pressure. The main advantages of ultrasonic welding are time saving, constant quality, cost saving and environmental friendliness. We also use hot plate welding or mirror welding. In this process the plastic parts are welded together by heat conduction. This is done by placing a plate (mirror) between the components in a heated state, then pressing the parts against the plate and thus melting them by the heat. Finally, the plate is removed and the plastic parts are welded together by pressing them together. The third method is hot gas welding or hot plate welding. This can be used to weld areas that cannot be reached with the other two processes.

What is subassembly or device assembly anyway?

Assembly is the process of putting together individual components to form complete parts or finished products (devices). An assembly consists of several (at least two) individual parts. Assembly can be manual, partially automated or fully automated. An assembly can consist purely of plastic parts, but can also contain other components, such as electrical accessories, cables, screws or rivets. We assemble everything for you from small assemblies to complete devices. In our equipment assembly we use many different methods such as gluing, riveting or welding. Assembly requires a high level of technical know-how, as different systems have to fit together and function in the end. For this we have a separate department with the expert personnel and the necessary assembly lines. We also manufacture jigs and fixtures for assembly in-house, which gives us a high degree of flexibility in this area. We are also happy to be your partner for exclusive assembly work in contract assembly. For necessary coating steps, which we cannot offer in-house, we cooperate with partners who have been with us for many years.

How does the pad printing process work in device assembly?

In pad printing, the printing ink is pressed onto the plastic part with a pad made of silicone rubber, which is elastic so that it can adapt perfectly to the component. Tampons are available in various sizes and shapes, so that they can be optimally selected to transfer the printed image exactly. Before the injection-molded part can be printed, however, a film and cliché must be created. The film transfers the print image to the cliché. The print image is recessed in the cliché after transfer. After completion, the cliché is mounted on the pad printing machine and the mechanical printing process can begin. For this purpose, the printing ink is applied to the cliché with a squeegee. This is done in a forward and backward motion. In the forward motion, the ink is floated on and in the backward motion, it is wiped off with a knife so that the ink is only in the recessed print image. After the ink transfer, the pad touches down on the cliché and takes over the ink from the printing cliché, moves to the plastic part, which is located in a printing device, and presses the print image onto the part by lowering it. This process can be repeated for greater intensity, or by changing the printing ink, multi-color printing is achieved.

What is hot stamping in device assembly?

Hot stamping is a coating process or pressure heating process in which we stamp a color layer onto a plastic part with the help of pressure and heat. Special foils (color pigment foil) are available for this purpose, which are applied between a hot cliché (embossing die) and the injection-molded part. The cliché presses itself onto the foil when hot and thus transfers a corresponding motif, usually lettering, onto the component. The hot stamping process is intended for permanent bonds. The print is also dishwasher safe. The hot stamping process is often also referred to as the finishing process, as the finished products often have a high-quality appearance as a result of this technique. In addition to the long durability of the printing, another advantage is the creation of a metallic gloss effect with the color pigment foils and hot stamping is suitable for both prototypes and small and large series production. Of course, the foils are not only available with a glossy effect, but also in countless colors, matte, brilliant or even with a hologram. What they all have in common, however, is that they are opaque.