Fertigungsverfahren für Produktentwicklung & Serie

Engineering, Manufacturing & DFM

From Technical Engineering to Series-Ready Manufacturing

The Right Manufacturing Process from the Start

We select suitable manufacturing processes based on material, production volume, tooling costs, geometry, tolerances, surface requirements and assembly, and apply design for manufacturing (DFM).

Injection Molding, TSG and Thermoforming

Plastics Processing

Sheet Metal, Die Casting, Extrusions and Tubing

Metalworking & Sheet Metal Design

Precision Machining of Metal and Plastic

CNC Milling & Turning

Prototypes and Complex Components

3D Printing & Additive Manufacturing

Joining Plastic and Metal Components

Joining, Welding & Bonding

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Ceramics, Wood, MDF, Glass and Laminated Safety Glass (LSG)

Special Materials & Specialized Processes

Ready to Turn Your Vision into Reality?

Feel free to contact us with your project details and requirements. We will review the scope, assess the development effort and provide a realistic and transparent quotation. Throughout the process, we keep both your vision and the overall project in focus.

Project Inquiry

Components Developed by ID DESIGN

Here you will find a selection of components that we have developed and supported through to series production. Every project brought its own technical requirements and individual challenges. Drawing on many years of experience, we can apply a broad range of proven solutions to guide development processes in a focused, efficient and practical way.

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We Develop for Manufacturing

We design for manufacturability and work across a wide range of manufacturing processes. A selection of these processes is presented here. Each manufacturing process requires a development approach tailored to its specific requirements to ensure a smooth transition from design and engineering to series production.

Design for Plastics Manufacturing

ID DESIGN develops plastic components tailored to function, material, manufacturing process and production volume. From simple housings to complex multi-component parts, we consider tooling, assembly, surface requirements and series production throughout the design process.

Plastic Injection Molding

Plastic injection molding is suitable for technically demanding components and enclosures produced in medium to very high volumes. We design the parts for efficient manufacturing and consider tooling concept, material, assembly, function and level of automation throughout the engineering process.

Materials

Depending on the application, we select and evaluate suitable plastics such as PC/ABS, ABS, PC, PA, PA-GF, PBT-GF, PP, TPU/TPE or silicone. Important requirements such as UV and weather resistance, impact strength, flammability ratings as well as visual and tactile requirements are also taken into account.

Engineering & DFM

When designing injection-molded parts, we consider all relevant geometric and tooling requirements. This includes wall thicknesses, ribbing, radii and draft angles as well as the prevention of sink marks, voids and warpage. Thin-walled components are also optimized specifically for stability and manufacturability.

For assembly and function, we integrate features such as screw bosses, direct plastic threads, threaded inserts, snap fits, snap hooks, annular snap joints and seals directly into the component geometry.

At the same time, we consider the requirements of the injection mold, including slides, lifters, forced demolding, collapsible cores, high-precision tooling, multi-cavity tooling and the positioning and design of gates.

Multi-Component Parts & Functional Integration

For complex plastic components, we integrate different materials and functions directly into the component design. This includes two-component injection molding, overmolding and the encapsulation of inserts or metal components, as well as combinations with TPU and TPE areas. Transparent components and integrated light guides are also designed specifically with regard to function, appearance and manufacturability.

Joining & Assembly

For safe and durable joining of plastic components, we consider suitable joining and assembly methods. These include ultrasonic and laser welding, adhesive bonding, mechanical snap connections, sealing concepts and screw connections. Depending on the application, specialized solutions such as sealing or joining aluminum membranes can also be integrated into the component development.

Surface Finish & Post-Processing

Surface finish and post-processing are considered as part of the component design. This includes color and material appearance, mold textures, high-gloss or matte finishes and functional surfaces. Depending on the requirements, painting, printing, marking and subsequent CNC machining are also taken into account.

Optimization

We specifically optimize both existing and new injection-molded parts for cost, weight and strength. This includes material usage, cycle time, tooling complexity, wall thicknesses, rib design, material selection and load paths. In the event of component failures, we also support root-cause analysis, for example through CT evaluation, fracture analysis, and the assessment of voids, sink marks, warpage and local stress concentrations.

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Blow Molding

Blow molding is well suited for lightweight, hollow plastic components produced in high volumes – from simple containers to complex technical parts. During development, we consider material selection, wall thickness distribution, threads and openings, demolding, parting lines and subsequent machining steps. Process integration, automation and compatibility with existing production equipment are also taken into account early in the design process.

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Thermoforming / Plastic Forming

Thermoforming is a cost-effective process for large-area plastic covers and enclosure parts, particularly for low to medium production volumes. We consider material selection, part depth, draw ratio, radii, wall thickness distribution, dimensional stability, tolerances and surface requirements. Demolding, undercuts, trimming concepts, fastening points, subsequent CNC machining and the integration or bonding of additional components are also incorporated into the component design.

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TSG / Structural Foam Injection Molding

Thermoplastic structural foam molding is particularly suitable for large, rigid plastic components with reduced weight and comparatively low tooling costs. The process allows for greater wall thicknesses, targeted use of ribs and reinforcements, and a reduced tendency for sink marks. Surface quality, paintability and the lower internal mold pressure are also considered during component design.

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Metal Design for Robust and Cost-Effective Components

Metal components and sheet metal structures enable robust, precise and cost-effective solutions for enclosures, frames, covers and technical assemblies. We consider manufacturing processes, material properties, stiffness, joining technology, assembly, tolerances and surface requirements as one integrated system.

Sheet Metal Fabrication & Design

Sheet metal design enables robust, precise and cost-effective components for enclosures, covers and technical assemblies. We consider manufacturing processes, material, stiffness, joining technology, assembly and surface requirements as one integrated system.

Manufacturing & Forming

When designing sheet metal parts, we consider the requirements of laser cutting, punching and bending. This includes suitable bending radii, bend reliefs, material thicknesses, minimum distances and manufacturing-friendly cutouts and contours. The material surface condition, requirements for visible surfaces, grinding direction and subsequent coatings are also taken into account.

Stiffness & Component Optimization

The stiffness of sheet metal parts is specifically influenced through geometry and material usage. Beads, bends, return flanges and local reinforcements enable stable components with minimal weight. Depending on the requirements, load paths can also be evaluated and designs optimized using FEA.

Fastening & Functional Integration

We integrate fastening and functional features directly into the sheet metal design. These include press-in nuts, press-in studs, rivet nuts, threads, mounting tabs and concealed screw connections. Mounts for electronics, cable routing, ventilation openings and other functional details are also integrated into the component geometry.

Enclosures, Doors & Service Access

For enclosures and machine covers, we consider not only manufacturing but also operation, assembly and service. Doors, flaps and removable panels are designed with regard to hinges, gap dimensions, stops, locking mechanisms and opening angles. At the same time, we ensure good accessibility and a clean, consistent overall appearance.

Assembly & Assemblies

Designing for assembly reduces effort and errors in later production. We optimize part count, positioning, tolerances and accessibility and consider suitable joining methods such as screwing, riveting, clinching or welding. The goal is to create robust assemblies with simple and reproducible assembly processes.

Technical Requirements

Depending on the application, sheet metal enclosures may need to meet additional technical requirements. These include EMC, heat dissipation, ventilation, grounding, corrosion protection as well as IP protection and sealing concepts. These requirements are coordinated with material selection, construction and manufacturing process.

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Tube Bending & Tube Structures

Tube structures are suitable for lightweight, stable and geometrically flexible assemblies. The design takes into account tube cross-section, wall thickness, bending radii, connections, tolerances and subsequent assembly.

Design for Bending

Tube diameter, wall thickness and bending radii are matched to the material and manufacturing process. We also consider deformation in the bend, possible changes in cross-section and minimum distances between bends, holes and other functional features.

Connection & Integration

Tube components are often combined with sheet metal, machined parts, profiles or additional tubes. We develop suitable welded, plug-in, screwed or clamped connections and consider mounts, fastening points and interfaces to the overall assembly.

Tolerances & Manufacturing

Bending processes influence angles, lengths and the position of subsequent features. We therefore consider manufacturing-appropriate tolerances, reference points and suitable machining sequences, particularly for holes, threads and functional surfaces that are machined after bending.

Surface Finishes & Post-Processing

Depending on the application, tube assemblies can be ground, blasted, painted, powder-coated or otherwise finished. Visible surfaces, weld seams and mechanical post-processing are also considered in accordance with the functional and visual requirements.

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Welded Assemblies

Welded assemblies are suitable for stable frames, enclosures and load-bearing structures made from sheet metal, tubes or profiles. Key considerations include weld-friendly component design, controlled tolerances, minimal distortion and reproducible manufacturing.

Design for Welding

Welded assemblies are designed so that individual parts can be positioned easily, joined securely and welded with good accessibility. We consider weld geometries, material thicknesses, butt and lap joints as well as combinations of sheet metal, tubes, profiles and machined parts.

Distortion, Tolerances & Fixtures

Heat input and shrinkage can have a significant effect on the dimensional accuracy of welded assemblies. We therefore consider welding sequence, reference systems, tolerances and suitable fixture concepts to achieve reproducible production and well-defined functional surfaces.

Strength & Component Optimization

Load paths, joints, profile cross-sections and weld positions are matched to the mechanical requirements of the assembly. The goal is a robust design with minimal material usage and a sensible distribution of reinforcements and weld seams.

Post-Processing & Surface Finish

Depending on the requirements, welded assemblies may be straightened, ground or mechanically post-processed after joining. Visible welds, functional surfaces and subsequent surface treatments such as blasting, painting, powder coating or corrosion protection are also considered during development.

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Die Casting

Die casting is suitable for complex metal components requiring high dimensional accuracy, good surface quality and cost-effective production at medium to high volumes. Typical applications include enclosures, structural components, brackets, heat sinks and parts for mechanical engineering, electronics and automotive applications.

Design for Die Casting

Wall thicknesses, radii, ribs, draft angles and parting lines are matched to the casting process. Demolding, slides, cores and undercuts are also designed so that complex geometries can be produced reliably and economically. With aluminum die casting, cooling fins and large-area structures can also be integrated directly, allowing the component to perform both mechanical and thermal functions.

Cost Efficiency & Functional Integration

Die casting can be a cost-effective alternative to CNC-machined or additively manufactured metal parts once production volume and component geometry justify the higher tooling costs. Key advantages include short cycle times, efficient material usage and the ability to integrate ribs, fastening points, cooling structures and other functions directly into the component. The economic break-even point depends strongly on component size, complexity, tooling effort, material and production volume.

Component Quality, Post-Processing & Surface Finish

Porosity, warpage and local material accumulations can significantly affect the quality of a die-cast component and must be considered in the design. Functional surfaces, threads, fits and sealing surfaces can subsequently be produced by CNC machining. Depending on the requirements, components can also be blasted, ground, painted, powder-coated or otherwise finished.

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Aluminum Extruded Profile

Aluminum extruded profiles are particularly suitable for elongated components with a constant cross-section. They enable cost-effective production of profiles, enclosure parts, frames and guide elements while combining low weight with high stiffness and good machinability.

Profile Design & Functional Integration

Cross-section, wall thicknesses, radii, hollow chambers and ribs are matched to the extrusion process. Targeted profile design allows stiffness, weight and material usage to be optimized. Guides, mounts, fastening features and cooling structures can be integrated directly into the profile, making it possible to replace multiple individual parts or extensively machined components.

Post-Processing & Surface Finish

After extrusion, profiles can be cut to length, drilled, milled or provided with threads and other functional features. Different component lengths can be produced from the same base profile. For technical and visual requirements, surface treatments such as anodizing, powder coating, grinding or brushing are available.

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Precision CNC Machining for Prototypes and Production Parts

CNC milling and turning enable the precise production of complex metal and plastic components – from prototypes and one-off parts to low- and medium-volume production. The process is particularly suitable for high dimensional accuracy, tight tolerances and components with functional surfaces, fits or complex geometries.

Design for Manufacturability

Component geometry, tool accessibility, setups, radii and machining directions have a major influence on manufacturing effort and part cost. Design for manufacturability can reduce machining steps, simplify setups and avoid unnecessary material removal. At the same time, we consider fits, threads, sealing surfaces and other functional areas.

Material, Surface Finish & Cost Efficiency

Depending on the application, materials such as aluminum, steel, stainless steel, brass and engineering plastics are used. Surfaces can subsequently be anodized, blasted, ground, polished or coated. Especially for prototypes and lower production volumes, CNC machining is often a cost-effective solution without tooling costs and can later serve as the basis for conversion to casting, extrusion or other series-production processes.

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Additive Manufacturing for Prototypes, Low-Volume Production and Complex Parts

3D printing enables the rapid, tool-free production of complex components made from plastic or metal. The process is particularly suitable for prototypes, functional models, low-volume production and geometries that would be difficult or costly to manufacture using conventional processes.

Component Design & Process Selection

Depending on the application, geometry, material and requirements are matched to the appropriate additive manufacturing process. We consider factors such as build orientation, wall thicknesses, support structures, tolerances, surface quality and mechanical loads. Depending on the component, processes such as FDM, SLA, SLS, MJF or metal-based additive manufacturing can be used.

Prototypes, Functional Parts & Low-Volume Production

Additive manufacturing enables rapid development cycles and early validation of geometry, assembly and function. In addition to visual models, durable functional parts, fixtures and low-volume production parts can also be manufactured. If required, components can subsequently be machined, ground, painted or combined with additional parts.

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Joining Technology for Durable and Process-Reliable Assemblies

The choice of joining process has a major influence on the strength, sealing, appearance, assembly and manufacturing cost of an assembly. We have practical experience with a range of processes, including laser welding, ultrasonic welding and friction welding, as well as mechanical and bonded joints.

Welding Processes & Design

Joint areas are specifically designed for the respective welding process. This includes accessibility, weld geometry, material pairing, tolerances and component positioning. In addition to laser and ultrasonic welding, we also consider processes such as rotary friction welding, where the joint is created through friction and the resulting heat.

Prototypes, Functional Parts & Low-Volume Production

Bonding can be useful, particularly when joining different materials, complex geometries or when additional sealing functions are required. At the same time, we assess adhesive joints critically because they introduce an additional and often sensitive manufacturing process. Dosing, surface preparation, positioning, curing time and handling can affect process reliability and repeatability. Where technically feasible, we therefore prefer mechanical, interlocking or weldable joints and use bonding specifically where it provides a clear functional advantage.

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Design for Plastics Manufacturing

Not every technical challenge can be solved effectively with conventional plastics or metals. Depending on the application, we also work with materials such as ceramics, glass, laminated safety glass, wood, MDF and hybrid material combinations. Key factors include function, mechanical load, manufacturability, surface requirements and integration into the final assembly.

Material-Specific Design

Special materials often place their own requirements on machining, fastening, tolerances and assembly. Brittle materials such as glass or ceramics require different design principles than wood-based materials or metal components. Holes, radii, support surfaces, clamping features and fastening points are therefore matched to the material and manufacturing process.

Specialized Processes & Material Combinations

Complex products often combine different materials and manufacturing processes. Examples include glass with metal frames, wood or MDF components combined with machined parts, and hybrid structures made from plastic, metal and other materials. The goal is a technically sound solution in which material selection, manufacturing and assembly are considered as one integrated system.