What we master

Our Expertise

Deep capabilities across the full thermoset polyurethane value chain
from tooling to serial production.

01
Core capability

Mold Design &
Manufacturing

We design and manufacture CNC-milled aluminium molds in-house from first concept sketch through to validated, production-ready tooling.

Every mold undergoes trial and testing before delivery.
Modular design principles allow rapid configuration changes and multi-cavity layouts.

CNC Milling Aluminium Modular In-house Testing
  • 2-part, 3-part (slide / tilt), 4-part configurations
  • Prototype to serial molds
  • Pre-serial molds that transition directly to production
  • Full 3D CAD/CAM design workflow
02
Turnkey solutions

Equipment &
Automation

We engineer complete automated production lines — from robotic systems and precision equipment to custom fixtures and control architecture. We seamlessly integrate all leading dosing unit and mixing head brands into our production line solutions.

Every system is designed for your specific production floor. Turnkey delivery means a single partner handles mechanical, electrical, software integration and ramp-up support.

Robotics & Motion Systems Collaborative Automation (Cobots) Digitalized Control Architecture Industry 4.0 & IIoT Turnkey Systems Custom Jigs & Fixtures
  • Automated foaming lines with integrated robotic handling
  • Seamless integration of leading dosing and mixing head systems
  • Custom part handling solutions
  • Advanced control and monitoring systems (PLC/SCADA/IIoT-ready)
03
Digital-first approach

Foaming
Simulation

FVM-based chemical foaming simulations let us optimize mold filling, predict density distribution and identify potential voids all before the first physical pour.

This simulation-driven approach means fewer prototyping iterations, less material waste, and pre-serial molds that go straight into production without redesign.

FVM Simulation Mold Fill Analysis Virtual Prototyping
  • Skip physical prototyping — go directly to pre-serial production
  • Optimize gate positions and venting
  • Predict foam flow, rise, and curing behavior
  • Reduce design risk through virtual validation before design freeze
04
In-house manufacturing

Serial
Production

Our in-house production facility covers advanced polyurethane foaming processes, including open- and closed-mold systems as well as front and back foaming, overfoaming, and structural sandwich constructions with injected foam cores.

We also support specialized approaches such as lost-core PU processes for overbraiding applications and in-situ foaming, across the full density range — from 15 g/L flexible foams to 1000+ g/L compact skins.

Open-cell Closed-cell 15–1000+ g/L Automotive Grade
  • Open- and closed-cell polyurethane foam processing
  • Broad density range — from flexible foams to rigid structural systems
  • Seamless transition from pre-series to full-scale production
  • End-to-end traceability and robust quality management
Additional capabilities

What else we master

01

PUR Processing Services

From concept to series production

We develop and manufacture tailored polyurethane foam components — from flexible to rigid structural systems, including open- and closed-cell materials.

  • End-to-end development from prototype to serial production
  • Precise material tuning across densities from 15 to 1000+ g/L
  • Enabling complex geometries and integrated features
  • Controlled processing and curing for consistent, high-performance parts
  • Integrated solutions including encapsulation, NVH damping, and thermal management
02

Measuring & Testing

Production-Integrated Quality Assurance

We develop and implement application-specific testing and validation systems for polyurethane components, ensuring consistent quality directly in production.

  • Custom fixtures and gauges for dimensional, fit & finish, and go/no-go validation
  • Cleanliness testing systems to verify residual contamination in components
  • Hardness and material validation (e.g., foam characterization with Zwick systems)
  • End-of-line testing solutions for repeatable, process-integrated quality control
03

Lightweight Technologies

Composites • PU cores • Weight reduction

Advanced materials and techniques that reduce weight while maintaining or enhancing performance.

  • High-strength composites
  • Optimized geometry for minimum material, maximum integrity
  • Precision machining
  • Overbraided composites with PU foam cores
04

Product Development

Concept • Prototyping • Validation • Serial

From initial concept through to serial production — we guide your product through every development stage.

  • 3D models and prototypes. Close collaboration to transform ideas into reality.
  • Functional prototypes to test durability and performance before mass production.
  • Mechanical testing, environmental testing and quality assurance checks.
  • Ongoing maintenance, upgrades and client support.

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