Manufacturer of Exporit foundry models and primary forming tools made of polystyrene foam for full-mould casting, tool and machine construction
Dörfelt Modellbau GmbH
ZwickauNew on Amplifa
About Dörfelt Modellbau
Dörfelt Modellbau GmbH is a family-owned mould and model making company based in Zwickau, today run in its fourth generation by master model maker Kay-Uwe Dörfelt. Its focus is on the manufacture of foundry models made of polystyrene foam (Exporit model making) – lost models for cast parts produced by the full-mould casting process – as well as the production of primary forming tools such as press, trimming and mould tools for the tool and machine construction industry. In addition, casting models for machine construction as well as demonstration and prototype models are produced. Model making is carried out on CNC gantry milling machines based on solid data, NC data sets, or conventionally based on 2D drawings; segmented production and assembly of model equipment with draft angles and core boxes are part of the service portfolio. In the company's own CAD/CAM department, data is processed in CATIA V5, Hyper-Cad and AutoCAD and NC programs are created; all common data formats such as VDAFS, IGES, DWG, DXF, Step and CATIAEXPORT can be processed. The company is certified to DIN EN ISO 9001:2015 and is a partner for foundries, tool and machine construction, and the automotive industry and its suppliers in the industrial region of southwestern Saxony.
- Site
- Zwickau
- Processes
- Production of foundry models from polystyrene foam (Exporit model making), lost models for, Production of primary forming tools (full-mould casting models for press tools, trimming and, CNC milling based on solid data, NC data sets or 2D drawings (model production, segmented, Assembly of primary forming tools and model equipment (with draft angles and core boxes), CAD/CAM processing: CAD design and NC program creation for model making equipment (CATIA, Production of casting models for machine construction, demonstration models, prototype models and, Foundry model making from polystyrene foam (Exporit model making) for full-mould casting, Production of primary forming tools (press, trimming and mould tools)
- Materials
- Polystyrene foam (Exporit model foam / Styropor), Model foam VFG 18 (fine-pored, fully gasifiable polystyrene foam material), Model foam VFG 18, CATIA V5, Hyper-Cad, AutoCAD
- Certificates
- DIN EN ISO 9001:2015, ISO 9001
- Founded
- 1924
- Industries
- Foundries, Toolmaking, Machine construction, Automotive industry and suppliers
- 01
CAD/CAM data preparation (solid data, NC programs)
- 02
CNC milling of models from polystyrene foam
- 03
Conventional production based on 2D drawings
- 04
Segmented production and joining
- 05
Assembly of primary forming tools and model equipment
- 06
Quality assurance to ISO 9001
Materials & Processes
Polystyrene foam (Exporit model foam / Styropor)
Base material for lost full-mould casting models and primary forming tools in Exporit model making.
Model foam VFG 18
Fine-pored, fully gasifiable polystyrene foam material with good machining properties for high-quality full-mould casting models.
CATIA V5, Hyper-Cad, AutoCAD
CAD systems for the design of model making equipment and NC program creation.
Locations
Zwickau
DEHeadquarters / Production
- Part weight / size
- Milling area up to 3900 × 2400 × 1400 mm
- Materials
- Polystyrene foam (Exporit model foam), VFG 18
- Bornemann BW 4010 CNC 3-axis gantry milling machine (3000 × 2200 × 1250 mm)
- Styrotec FS 10 CNC 3-axis gantry milling machine (3900 × 2400 × 1400 mm)
- Bornemann hand milling machines
- Band saw
- Jointer planer
- Disc sanders
- Dust extraction system
- SpinFire/3DView viewer workstations
Parts & Models
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Production of foundry models from polystyrene foam (Exporit model making), lost models forCasting | – | – | – | – | Polystyrene foam (Exporit model foam), Model foam VFG 18 (fine-pored polystyrene foam |
| Production of primary forming tools (full-mould casting models for press tools, trimming andCasting | – | – | – | – | Polystyrene foam (Styropor) |
| CNC milling based on solid data, NC data sets or 2D drawings (model production, segmentedMachining | – | – | – | – | Polystyrene foam (Exporit model foam) |
| Assembly of primary forming tools and model equipment (with draft angles and core boxes)Assembly | – | – | – | – | Polystyrene foam (Exporit model foam) |
| CAD/CAM processing: CAD design and NC program creation for model making equipment (CATIAEngineering | – | – | – | – | – |
| Production of casting models for machine construction, demonstration models, prototype models andCasting | – | – | – | – | Polystyrene |
8 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| CNC 3-axis gantry milling machine | Bornemann BW 4010 | 1 | 3000 x 2200 x 1250 mm | – | Zwickau |
| CNC 3-axis gantry milling machine | Styrotec FS 10 | 1 | 3900 x 2400 x 1400 mm | – | Zwickau |
| Hand milling machine | Bornemann | – | – | – | Zwickau |
| Band saw | – | – | – | – | Zwickau |
| Jointer planer | – | – | – | – | Zwickau |
| Disc sander | – | – | – | – | Zwickau |
| Dust extraction system | – | 1 | – | 2011 | Zwickau |
| Viewer workstations (CAD data visualization) | SpinFire/3DView | – | – | – | Zwickau |
Additional services
Reference customers
Quality
The company is certified to DIN EN ISO 9001:2015 (certificate de013391-1). Quality-relevant processes are documented, sources of errors are systematically checked after each work step, and the order throughput is made transparent for customers.
| Evidence | Zwickau |
|---|---|
| ISO 9001 |
Company History
- 1924
Foundation of the company Dörfelt & Hentschel Modellfabrikation by Paul Gerhard Dörfelt with partner Hentschel in Oberhohndorf (Zwickau).
- 1929
Great Depression; in 1931 separation from the partner, Paul Gerhard Dörfelt becomes sole managing director.
- 1938
Construction of a new workshop on the company's own property on Wildenfelser Straße in Zwickau with 100 m² of production space.
- 1946
After the founder's death, the business is taken over by Herbert Dörfelt, master of the model makers' guild; managing director until 1982.
- 1982
The business is taken over by Dipl.-Ing. Bernd Dörfelt with five employees; managing director until 2012. During this period, among other things, all models for the cast parts of a marine steam engine were produced.
- 1986
Expansion of production space by 60 m².
- 1991
Foundation of Modellbau Dörfelt GmbH on 21.02.1991; entry into Exporit model making and production with CAD/CATIA.
- 1993
Kay-Uwe Dörfelt joins the company as a trained model maker.
- 1994/95
Construction of a new production hall and an office building.
- 2011
Expansion of the machine equipment: new dust extraction system, new CNC milling machine, conversion of the assembly hall.
- 2012
The business is taken over by master model maker Kay-Uwe Dörfelt.