Technical deep-drawn plastic parts – from engineering and toolmaking through to assembled series production
Dr. Karl Gert Fischer GmbH & Co. KG
Overath-ImmekeppelNew on Amplifa
About Dr. Fischer Kunststofftechnik
Dr. Karl Gert Fischer GmbH & Co. KG is a family-owned company based in Overath-Immekeppel near Cologne, specialising in vacuum deep-drawing (thermoforming) of plastics. The company manufactures large-surface and technically demanding moulded parts such as claddings, housings, hoods, covers, plastic trays and load carriers with component dimensions up to 2200 × 1300 × 620 mm from material thicknesses of 1 to 12 mm. In addition to deep drawing, the portfolio includes machining of deep-drawn parts on 5-axis CNC milling machines, in-house toolmaking for thermoforming tools, clamping fixtures and gauges made of aluminium alloys, engineering services from component optimisation to tool design, as well as assembly and bonding with 1K and 2K adhesives. As a system supplier, the company kitting complete product sets including purchased injection-moulded and metal components. Customers come, among others, from machinery and equipment manufacturing, construction and agricultural machinery, commercial vehicles, electrical engineering, medical and laboratory technology, the furniture industry, traffic engineering, and the solar systems and energy storage sector. Production has taken place since 1996 on a four-building factory site close to the autobahn; the company has been continuously certified to DIN EN ISO 9001 since 2002.
- Site
- Overath-Immekeppel
- Processes
- Deep drawing (thermoforming, vacuum deep drawing), CNC milling of plastic parts (5-axis), Engineering (component optimisation, thermoforming tool design, milling holders,, Assembly (bonding 1K/2K, fasteners, seals, labels, snap fittings, screws,, Kitting (assembly of product sets/packaging units, system supplier, purchased parts, Toolmaking (manufacture and maintenance of thermoforming tools, clamping fixtures,, Thermoforming/deep drawing (vacuum deep drawing), CNC milling (5-axis)
- Materials
- PS (Polystyrene), ABS, ABS/PMMA, PET-G, PC (Polycarbonate), PE (Polyethylene), PP (Polypropylene), PVC
- Certificates
- DIN EN ISO 9001
- Founded
- 1973
- Industries
- Construction and agricultural machinery, Machinery and equipment manufacturing, Electrical engineering, Furniture industry/shopfitting, Motorcycles and scooters, Medical and laboratory technology
- 01
Engineering (component optimisation, consulting)
- 02
Toolmaking (thermoforming tools, fixtures, gauges)
- 03
Thermoforming / vacuum deep drawing
- 04
CNC milling (5-axis machining)
- 05
Assembly & bonding
- 06
Kitting
- 07
Logistics/delivery
Materials and Processes
Thermoforming / Vacuum Deep Drawing
Forming of thermoplastics into three-dimensional moulded parts up to 2200 × 1300 × 620 mm with raw material thicknesses of 1 to 12 mm.
ABS (Acrylonitrile Butadiene Styrene)
Resilient standard material for housings, claddings and visible parts in machinery and vehicle construction.
ABS/PMMA
Two-layer material with a high-quality PMMA surface for demanding visible-part applications.
PC (Polycarbonate)
Tough and impact-resistant, suitable for heavily stressed claddings and protective enclosures.
PET-G
Transparent thermoplastic for hoods, covers and inspection windows.
PS (Polystyrene)
Cost-effective material for technical moulded parts and packaging units.
PE (Polyethylene)
Chemical-resistant and robust, used among other things for trays and containers.
PP (Polypropylene)
Media-resistant thermoplastic for technical components with flexibility requirements.
PVC (Polyvinyl Chloride)
Flame-retardant material for housings and claddings with fire-protection requirements.
Aluminium alloys (toolmaking)
Material for thermoforming tools, clamping fixtures and milling holders in the in-house toolmaking shop.
Aluminium-resin combination
Tool material for special cases, depending on lot size and component requirements.
Overath-Immekeppel Site
Overath-Immekeppel
DEProduction, administration and warehouse in four buildings; fourth building completed in 2020 specifically for
- Part weight / size
- max. component 2200 × 1300 × 620 mm
- Lot size
- Lot sizes from approx. 100 parts/annual requirement to 20,000
- Materials
- PS, ABS, ABS/PMMA, PET-G, PC, PE, PP, PVC
- Fully automated deep-drawing machines
- 5-axis CNC milling machines
- Dosing system for 2K adhesives
- ERP system with production control centre (DMS, APS)
Deep-Drawn Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Deep drawing (thermoforming, vacuum deep drawing)Plastics | – | 2200 mm × 1300 mm × 620 mm | – | 100 – 20,000 (annual requirement) | PS, ABS, ABS/PMMA, PET-G, PC, PE, PP, PVC |
| CNC milling of plastic parts (5-axis)Machining | – | – | – | – | PS, ABS, ABS/PMMA, PET-G, PC, PE, PP, PVC |
| Engineering (component optimisation, thermoforming tool design, milling holders,Engineering | – | – | – | – | – |
| Assembly (bonding 1K/2K, fasteners, seals, labels, snap fittings, screws,Assembly | – | – | – | – | – |
| Kitting (assembly of product sets/packaging units, system supplier, purchased partsAssembly | – | – | – | – | – |
| Toolmaking (manufacture and maintenance of thermoforming tools, clamping fixtures,Toolmaking | – | – | – | – | Aluminium alloys, Aluminium-resin combination |
2 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 5-axis CNC milling machine | – | – | – | – | Overath-Immekeppel |
| Deep-drawing machine (fully automated) | – | – | max. component 2200 x 1300 x 620 mm, raw material thickness 1-12 mm | – | Overath-Immekeppel |
Additional services
Quality
The company has been continuously certified to DIN EN ISO 9001 since 2002 and works with a high-performance ERP system with an integrated production control centre that manages the process from material procurement to delivery. The in-house toolmaking shop, with the manufacture and maintenance of all tools and fixtures, ensures consistently high product quality and short response times for changes.
| Evidence | Overath-Immekeppel |
|---|---|
| DIN EN ISO 9001 |
Company History
- 1973
Founded as a deep-drawing company by Dr. Karl Gert Fischer as a sole proprietorship with two employees; first location in the Cologne-Niehl industrial area.
- 1996
Purchase of a plot of land in Overath and conversion of existing industrial buildings; relocation to a site near the autobahn.
- 2002
First certification to DIN EN ISO 9001, continuously certified ever since.
- 2010
Constantin Fischer joins the company; focus on further development and automation of production processes (ERP, DMS, APS).
- 2012
Constantin Fischer takes over his father's business shares, supported by Thomas Bexte.
- 2016
Introduction of a new company logo.
- 2020
Completion of the fourth building: production and warehouse hall dedicated specifically to thermoforming.
- 2024
Approval of a new development plan, purchase of the neighbouring plot and planning of additional expansions.