Custom production of molded plastic parts

Plastic injection molding

The processing of free-flowing thermosets and various thermoplastics on modern production equipment has been a daily routine for B&S for many years.

Small series as well as large series requested by the customer can be flexibly implemented.

Innovation

We develop, design & and realise your ideas through our own mold construction.

Flexibility

In case of special regulations or market changes, we are able to quickly intervene in the production process.

Quality assurance

Individualised hardware and software testing systems ensure the quality of every single product.

Bernhardt & Schulte as a reliable partner

Development, construction and production of precise plastic parts

Bernhardt & Schulte has been an owner-managed family business since its foundation in 1919. In addition to the manufacture of rotary switches, we develop, design and produce plastic parts of the highest quality and precision, including the required molds.

Precise plastic parts for your project

What is plastic injection molding?

Plastic injection molding is a process for manufacturing plastic products by injecting molten plastic into a mould. Because of its fast, precise and efficient production process, it is one of the most popular methods for manufacturing plastic products.

Injection molding is a versatile manufacturing process that can be used to make products of all shapes and sizes. It is particularly well suited for products with complex designs.

Plastic injection molding is used in many industries, such as automotive, electronics, furniture and medical, and is ideal for high-volume production.

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Automated injection molding at B&S

How does injection molding work?

The plastic injection molding process begins with the melting of the plastic into a liquid mold. This is done at Bernhardt & Schulte with a large cylinder and a screw system.

Once the plastic has melted, it is injected at high pressure into the desired mold. After the mold is cooled down, the plastic solidifies into the desired shape. The finished molded part is then ejected.

In the first step, the plastic granulate will be filled into a funnel. The screw pulls the granulate out of the hopper and melts it. The material plasticises due to the heated screw barrels. The material then moves through the screw into the front part of the cylinder, where it subsequently collects behind the nozzle.

As soon as the mold is closed, the tip of the screw moves in front of the mold nozzle. The compound is then injected into the mold under pressure.

Due to cooling, the mass in the mold shrinks. In order to avoid sink marks and cavities, further compound is injected into the mold with additional pressure. The molding compound is then cooled (thermoplastics) or heated (thermosets) in the mold.

At the end of the selected cooling or heating time, the mold is opened and the molded part is removed or ejected. After closing the mold again, the next shot can be taken.

Custom plastic injection molding

Our plastic injection molding service

From prototype to production, we at Bernhardt & Schulte are the sole contact for your serial production using plastic injection molding. Our in-house mold construction enables us to intervene in production processes as quickly as possible.

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Individual switching systems in line with customer requirements provide us with the opportunity to prove our capabilities in the electrical and electronics industry. 

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Technical molded parts

For required complex functions, B&S produces technical plastic molded parts using the injection molding process for every industrial sector.

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Overmolding of inserts

With B&S injection molding technology, inserts can be reliably overmolded around complex components with thermoset or thermoplastic.

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We manufacture high-quality and custom tools and molds for your field of application. You will benefit from B&S many years of expertise.

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Customized hardware and software testing systems

Quality control of the plastic injection molded parts

A company that achieves the highest standards in production must be just as ambitious when it comes to quality assurance. In order to test every mold and every assembly to the best possible standard, Bernhardt & Schulte develops devices and software for pending tests both in-house and, of course, in close cooperation with clients. Among other things, we use a coordinate measurement machine, profile projectors, length measurement devices, pressure and traction measurements and torque measurements. We conduct tests while production is ongoing, working with a CAQ system, with EmpBs according to the VDA, IMDS and quality molds. As requested, technical and visual tests are carried out as random checks or using 100% testing. Special workstations have been set up for this purpose on which the electrical functions can be tested.

Custom plastic injection molding

Plastic molded parts for a wide range of industries

High precision plastic parts are used in almost every branch of industry. Our qualified team of developers, engineers, designers and technicians look forward to every new challenge. We aim to prove that we are among the best. Every day, with every product and in every task.

Plastic injection molding materials

Which plastics are suitable for injection molding?

A wide range of thermosets, thermoplastics and elastomers are suitable for plastic injection molding. At Bernhardt & Schulte, we focus primarily on plastic injection moulding with thermosets and thermoplastics.

Thermoset

Thermoplastics

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Hybrid components

Combination of thermosets and thermoplastics

We have developed a more advanced process in which thermoset components can be overmolded with thermoplastic. This produces extremely robust and dimensionally stable components with a temperature-resistant shell.

The production line we co-developed consists of an 8-cavity mold, an 8-cavity hot runner manifold and a fully automatic assembly line. On it, we manufacture switch covers for starter relays, among other things. These are used in start-stop starters in passenger cars and reduce CO2 emissions.

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Moving your Product from prototype to production
How we process your request

1.
Your request

Send us a request for your project using the contact form on this page.

2.
Internal coordination

With the information from your request, we carry out a feasibility analysis. In doing so, we carefully check whether the project can be implemented technically, commercially and in terms of time.

3.
Offer

After a positive evaluation of the manufacturability analysis, we will prepare a mold calculation and a checklist. We will then send you the offer.

4.
Mold construction

Provided that the offer has been accepted, we start with the mold production.

5.
Production of the samples

Once the required molds have been completed, we initiate the production of the samples in close consultation.

6.
Start of serial production

As soon as quality assurance has approved the sample and it meets your expectations, we will begin the serial production.

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Environmentally friendly
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Management system

We are certified

Products that carry our name really work. That‘s because they
are innovative, safe to work with and long-lasting. They are
tested for the highest quality. This is the yardstick by which
we measure ourselves. We are happy to provide evidence of
this with:

DIN EN-ISO 9001 certification

Send us request with no obligation
Contact

Do you have questions about our services, products or processes? We will gladly help you!