KTL® application examples

Application example for our KTL services from Rodgau. The results may already answer some of your questions.
To your contact person

KTL INJECTION

Injection molding Hybrid components

  • Integration of copper contacts in an injection molded part
  • 100% repeat accuracy when positioning the Cu contact in series production

Solution

  • Design of the injection molded part and the optimum position of the contacts, including procurement of the contacts
  • Development and construction of the necessary mold design
  • Form-fit, tight connection between contacts and plastic part in a single production step

Result for you

  • Ready-to-use injection molded part for initial prototype or small series tests

KTL INJECTION

Injection molding LSR (Liquid Silicone Rubber)

  • Sealing of two components with integrated seal in the injection-molded part

Solution

  • Tight connection between the plastic part and the rest of the assembly
  • Injection-molded design of the part for attaching the component seal
  • Short throughput time thanks to in-house system technology

Result for you

  • Ready-to-use injection molded part for initial prototype or small series tests
  • One contact for injection molding and seal

KTL AM

Additive manufacturing

  • Suction and transport units adapted to free-form surfaces
  • Simplification of the existing design, optimization of the assembly
  • Integration of functionalities
  • Space-optimized component

Solution

  • Design and construction of the 3D printed parts, perfectly adapted to the free-form surface
  • Integrated vacuum channels in the component, thereby simplifying and reducing the weight of the assembly
  • Reduction in cycle times due to mass reduction

The result for you

  • Increased machine efficiency thanks to short set-up times and increased cycle frequency
  • Individually tailored design of the component
  • Smaller shape changes are easy to produce
  • Long service life for >100 thousand cycles
  • Lightweight construction through the use of high-quality PA12 material

KTL AM

Medical orthosis

  • Adaptation of the orthosis to the patient's specific situation
  • Good support with high wearing comfort
  • Lightweight and easy to wear support for injuries

Solution

  • 3D-printed orthoses are lightweight and breathable, preventing skin irritation
  • Individually tailored to the patient's anatomy for optimum treatment
  • Padded zones possible
  • less time required, as production is directly from the 3D scan
  • Can also be dyed

Result for you

  • Fast and individual help for the patient thanks to the scan
  • Inexpensive alternative to previous methods (plaster casts)
  • Greater acceptance among patients

KTL MODELLING

Model making demonstrator

  • Driving simulation trade fair object for the IAA as a show and experience model
  • Completely realized according to specified design

Solution

  • Manufacture of the molds and production of the blanks
  • Machining of the free-form surfaces
  • Laminating and finishing with Class A surface
  • Production of 3D printed parts from in-house additive manufacturing
  • Assembly of the complete trade fair object

Result for you

  • Complete delivery of the demonstration model from a single source
  • End product manufactured precisely according to customer specifications

KTL MODELLING

Model making using the RIMFLEX process

  • For functional and assembly tests, the lowest possible costs for a limited number of components
  • For functional and assembly tests, lowest possible costs for a limited number of components
  • Exact mapping of the intended design specifications

Solution

  • Polyurethane component using the RIMFLEX process
  • Stiffer molding prevents deformation and thus ensures dimensional accuracy and wall thickness of the component
  • Improved impact strength, heat resistance possible thanks to short glass fiber
  • Casting process suitable for series production

Result for you

  • Detailed reproduction of the design model
  • Consistently high surface quality for the planned quantity
  • No sudden increases in unit costs due to additional molds required

KTL MODELLING

Machining

  • Machining of aluminum components with large dimensions
  • Production and assembly of small elements in large quantities

Solution

  • High machining volume thanks to automated 5-axis milling production
  • Use of our portal milling machine (travel up to 1500x3000x6000mm) for large workpieces
  • Assembly of the complete module

Result for you

  • Delivery of the complete assembly from a single source
  • Perfect repeat accuracy thanks to the use of state-of-the-art production steps