acad group GmbH

Development of medical devices

acad systems Innovative housing solutions for medical devices Development and manufacturing of small series. Time to Market: We help you to bring your idea to market in the shortest possible time, even for small quantities. We develop innovative housing solutions, cooperate with electronics and firmware firmware developers, produce small plastic batches of up to 2,000 parts, procure all supplier parts, ensure validation and evaluation, and support you in the and support you in the transfer to larger series. Housing development: Are you looking for a suitable housing that can meet your individual requirements in terms of tightness, shock protection, temperature, chemical resistance and EMC protection as well as in terms of look and feel? The market for standard enclosures quickly reaches its limits in this respect, and custom-made products are usually not profitable, especially for small quantities. acad sytems offers effective and efficient enclosure solutions tailored to your needs. With our 5-phase development we systematically secure each step of the development. After completion and analysis of each individual phase, you decide when and how to proceed with the next phase, which means a minimization of your investment and development risk. Small batch production: Do you have an already developed product idea waiting to go to market? Your product is to be tested in the field with a small series? The total quantity of your product does not exceed the limit of 2,000 parts? Thanks to our special express injection molding system, we can provide you with customized plastic specials even for small quantities up to 2,000 pieces, which are adapted to budget, number of pieces, operational application and customer target customer target group. We cost-consciously procure all other necessary components and materials.

Express prototype injection molding

acad prototyping Making ideas reality - prototypes in injection molding technology Driven by Improvement: Progress is not achieved by definition, but only by proof. Prototypes are the ideal way to obtain product confirmation and validation through a variety of testing possibilities and to identify further development needs. The selection of the manufacturing process for prototypes depends on the maturity of the product development and the required validation. Whenever it is necessary to test series-identical strength and rigidity, as well as the processing influences typical of injection molding, original series materials and injection molding technology are the first choice. Prototypes for product development: acad prototyping quickly and cost-effectively produces plastic injection molding prototypes from original series materials that provide all the necessary results for validation, confirmation or further development of the product and manufacturing technology. Our plastic parts originate from a unique tooling and manufacturing technology that is close to the development stage. quality as well as time and cost advantages for product development. What we offer: Our customers benefit from short lead times, favorable tooling costs and ease of modification. Initial samples of individual parts or entire assemblies can be completed within as little as 5 AT. These can be used to comprehensively assess warpage, sink marks, yield lines, dimensions and tolerances, as well as the basic function, strength and rigidity of the article. to be comprehensively assessed. In addition, small test assemblies from 50 to 2,000 parts can be produced extremely economically due to the low tooling costs, even with high article complexity.

Automotive Interior Development

acad engineering Product development for automotive interiors Driven by Evolution: Do you want to ensure a competitive edge over the competition with unconventional solutions? We provide you with competent advice and accompany even complex projects in a goal-oriented manner until they are successfully completed. We place particular emphasis on systematic project management. Shortest development times: We take over all services for the product development process to achieve product series maturity. Our development processes are fast, cost-effective and completely tailored to the needs of our customers and their products. Design expertise: We value good design. We recognized the importance of CAD/CAM at an early stage and, through continuous training of our employees, we have we are constantly expanding our know-how in this field. We work with the most important CAD systems (CATIA, NX) to create customer-oriented design solutions. Our specialty is the design of free-form surfaces and the development of complex plastic parts with a high degree of functional integration. We develop concepts for plastic products and accompany their development processes for OEMs and their suppliers. Our extensive range of services includes prototyping and prototype construction of concept and principle samples. Examples of our work: - Product development for automotive interiors - FEM calculations - Tolerance analyses - moldflow analyses - reverse engineering - Project and quality management - own functional prototyping - drawing production

Patent: Hybrid structural components by combining LFT plastic injection molding (long fiber thermoplastic) & additive manufactured continuous fiber inserts.

Injection molded plastic parts can be made lightweight in a number of ways. A new strategie for reducing the weight of injection molded parts is shown by our sample case study: With a special process, patented by acad, injection molded parts can be strengthened locally in an effective and sustainably simple way. By combining LFT (Long Fiber Thermoplastic) and additively manufactured continuous fiber inserts, it is possible to produce high-strength and considerably lighter structural components by serial injection molding. Main Advantages: - Local load-optimized and automated integration of continuous fibers in LFT injection molded components at the hot spots - additive manufacturing of semi-finished products from pre-impregnated continuous fibers - optimal load transfer due to compatible matrix materials for inserts and injection molding material - elimination of weak points such as flow lines in LFT injection molded components

Contolunit Robotic System Medtronic

e-mobility - orange parts

High requirements for the material With the radical shift from internal combustion engines to electric drives in vehicle construction, the demands on the plastics used have changed dramatically. For vehicles to keep up with the latest trends in charging times and range, they must be able to withstand voltages of up to 1,000 volts. The color orange is used in electric vehicles to clearly indicate which plastic-sheathed and current-carrying components are exposed to higher voltages. These plastics must meet much higher requirements for thermal aging resistance, flame retardancy and creepage resistance.Specially developed plastics are available for this purpose, such as Xytron PPS high dielectric strength from DSM or the PA6 compound Durethan BKV45FN04 with 45% glass fiber from LANXESS. We have already gained experience with these materials in several projects. Even with the high material requirements, acad is able to realize your pre-series, ramp-up or small series efficiently, quickly and in a cost-effectively.

Hybrid components

Hybrid injection molding technology creates a form-fit connection between a thermoplastic and other components made of materials such as metal, ceramic, glass, fabric or electronic components in a single process step. This type of joint replaces the traditional joining or bonding of other plastic components, eliminating additional process steps. Wherever a force needs to be transmitted as precisely as possible, a low-wear metal bearing makes sense; where signals need to be transmitted, cables and connectors need to be firmly connected to a component; where a screw connection is subject to mechanical stress and would eventually tear out of the plastic, a combination of plastic and metal is the answer. The stable positioning of the inserts in the injection mold plays an important role in ensuring the accurate fit and longevity of the entire component. A distinction is made between insert and outsert technology. In insert technology, metal parts are incorporated into a part that is primarily plastic. In outsert technology, the majority of the part consists of another component onto which plastic elements are molded.acad's Rapid Molding System enables the cost-effective use of inserts, even in small quantities, by using gravity for positioning without the need for complex handling systems. acad can support you in the field of hybrid injection molding technology and advise you comprehensively on your questions.

Multi-component parts - hard-soft

LFT plastic injection molding (Long Fiber Thermoplastic)

Injection molded prototypes up to 700g

Mit unserem Rapid Moulding System RMS® kann ab einer wirtschaftlichen Losgröße von einem Schuss bis zu 2.000 Schuss garantiert produziert werden. Bei geringerer Bauteilkomplexität können diese Schusszahlen auch höher liegen. Die derzeitige maximale Bauteilgröße ist 600mm x 290mm x 250mm, das maximale Spritzgewicht 700 Gramm pro Schuss.

Are you looking for the best partner for your injection molding prototype production?

Watch the video to learn about the many possibilities and the full range of acad's unique “Rapid Moulding System” to optimize the development maturity of your plastic parts.