Tool and mold making for thermoforming, foaming, vulcanization, rotational casting, composites, molded wood and concrete
FORMOTiON GmbH
WilnsdorfNew on Amplifa
Tool and mold making from Wilnsdorf
FORMOTiON GmbH in Wilnsdorf (Siegerland) is a specialized company for tool and mold making with eight employees. The company develops and manufactures mold tools for thermoforming, foaming processes, vulcanization, rotational molding as well as composite presses for carbon, CFRP and organo sheets; additionally, concrete molds and formwork, molded-wood press molds and CNC-milled wood parts are offered. Production is carried out entirely in-house: from CAD design and CAM programming (VISI) through 3- and 5-axis milling, machining and surface treatment to tool assembly. Materials processed include, alongside aluminium and hardened steel, plastics (e.g. PE, PP, PA, EPP, PUR, EPS, silicone, rubber) and composite materials. Customers come from industries such as packaging, automotive, medical technology, aerospace, furniture and furniture design, architecture, concrete and facade construction as well as art and design. Since the relocation in 2018, processes have been digitally networked and organized almost paperlessly in line with Industry 4.0 principles.
- Site
- Wilnsdorf
- Processes
- Thermoforming tools / thermoforming (vacuum/pressure deep drawing), Foam tools (PE, EPP, PUR, EPS, RIM), Vulcanization tools (rubber injection, compression, transfer, platen-heating tools, silicone molds), Rotational molds / rotocasting molds, Composite molds / pressing of carbon, CFRP and organo sheets, Molded-wood press molds (2D/3D) and small series production, CNC milling of wood parts & prototypes, Concrete molds / formwork / matrices / master models for fair-faced concrete
- Materials
- Aluminium, Plastics, Composite materials, Steel (hardened, mold tools), PE (polyethylene), LLDPE, HDPE, XLPE (cross-linkable PE)
- Certificates
- ISO 9001:2015, ISO 14001, ISO 9001
- Founded
- 1987
- Employees
- 8
- Industries
- Packaging industry, Automotive industry, Medical technology, Consumer goods industry, Aerospace industry, Agriculture and construction / mechanical engineering
- 01
Engineering / co-engineering
- 02
CAD design
- 03
CAM programming (VISI)
- 04
CNC milling (3-/5-axis) and machining
- 05
Surface treatment (grinding, polishing, blasting, coating)
- 06
Tool making and assembly
- 07
Quality inspection and delivery
- 08
Maintenance and care of tools
Materials and processes
Aluminium
Material for thermoforming, foaming and rotational molds with high thermal conductivity and low weight.
Steel (hardened)
Mold steel for highly stressed mold tools in continuous use.
PE (LLDPE, HDPE, XLPE)
Standard materials for rotational molding of hollow bodies such as tanks and containers.
PP, PA 6, PA 12
Thermoplastics for rotational molding with higher temperature or strength requirements.
EPP, EPS, PUR, RIM
Foaming and reaction materials for which FORMOTiON manufactures foam tools up to 5 t.
Rubber, silicone
Elastomers for vulcanization, injection, compression and transfer tools as well as silicone molds.
Carbon, CFRP, organo sheet
Fiber composite materials for which composite press molds are developed and built.
Wood / molded wood, veneer
Material for press molds, small series and design components.
PU, wood, silicone (concrete molds)
Mold materials for fair-faced concrete formwork with tolerances below 0.1 mm.
Acrylic glass, resin, metal
Materials for milled design objects and art projects (FORMOTiON Art).
Locations
Wilnsdorf
DEHeadquarters with production (tool and mold making)
- Part weight / size
- Alu foam tools up to 5 t; concrete molds up to 2400 × 1400 ×
- Lot size
- Prototype, pre-production, series
- Materials
- Aluminium, steel, plastics, composite materials, wood
- 5-axis machining center (2300 × 1300 mm, FCS zero-point clamping system)
- several 3-axis CNC milling machines (up to 2000 × 800 mm)
- conventional milling, turning, drilling and grinding machines
- milling machining centers with automation and coolant replenishment
- CAM software VISI
- FCS zero-point clamping system
Tools and components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Thermoforming tools / thermoforming (vacuum/pressure deep drawing)Forming | – | – | – | – | Plastics, Aluminium |
| Foam tools (PE, EPP, PUR, EPS, RIM)Plastics | – | – | Alu foam tools up to a maximum of 5 t | – | PE, EPP, PUR, EPS, RIM, Aluminium |
| Vulcanization tools (rubber injection, compression, transfer, platen-heating tools, silicone molds)Plastics | – | – | – | – | Rubber, Silicone |
| Rotational molds / rotocasting moldsPlastics | – | – | – | – | LLDPE, HDPE, XLPE, PP, PA 6, PA 12, PVC plastisol, EVA, Aluminium |
| Composite molds / pressing of carbon, CFRP and organo sheetsForming | – | – | – | – | Carbon, CFRP, Organo sheet |
| Molded-wood press molds (2D/3D) and small series productionForming | – | – | – | – | Wood, Veneer, Solid wood |
| CNC milling of wood parts & prototypesMachining | – | – | – | – | Wood |
| Concrete molds / formwork / matrices / master models for fair-faced concreteCasting | < 0.1 mm | 2400 × 1400 × 800 mm × 1400 mm × 800 mm | up to 50+ uses (depending on material) | – | Aluminium, PU, Wood, Silicone |
| 3-axis millingMachining | – | 2000 mm x 800 mm × 800 mm | – | – | Aluminium, Plastics, Composite materials |
| 5-axis millingMachining | – | 2300 mm x 1300 mm × 1300 mm | – | – | Aluminium, Plastics, Composite materials |
| Conventional turning, drilling, grinding (machining)Machining | – | – | up to 5 t tool weight | – | Aluminium, Steel |
| Surface treatment (grinding, anodizing, painting, powder coating, glass bead blasting)Surface | – | – | – | – | Aluminium, Metal, Wood, Resin, Acrylic glass |
| Tool making / tool assemblyAssembly | – | – | – | – | Steel, Aluminium |
| Engineering, CAD design, CAM programmingEngineering | – | – | – | – | – |
| Milling of sculptures, design objects, artworks (FORMOTiON Art)Machining | – | – | – | – | Wood, Metal, Resin, Acrylic glass, Carbon |
6 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 5-axis machining center | – | – | Travel 2300 mm x 1300 mm, with FCS zero-point clamping system | – | Wilnsdorf |
| 3-axis CNC milling machines | – | several | largest travel 2000 mm x 800 mm, FCS zero-point clamping system | – | Wilnsdorf |
| Milling machines (conventional, turning, drilling, grinding) | – | – | – | – | Wilnsdorf |
| Milling machining centers with automated machining and coolant replenishment | – | – | – | – | Wilnsdorf |
| CAM software VISI | VISI | – | – | – | Wilnsdorf |
| FCS zero-point clamping system | FCS | – | – | – | Wilnsdorf |
Additional services
Reference customers
Quality and certification
FORMOTiON has been working with a quality management system certified to ISO 9001:2015 since 2011; quality assurance runs through the design, production and final inspection of every tool. Modern metrology, sensor-based machine monitoring and paperless digital processes ensure tight tolerances and repeat accuracy.
| Evidence | Wilnsdorf |
|---|---|
| ISO 9001 | |
| ISO 14001 |
History
- 1987
Founding of FORMOTiON; initial focus on prototype and series molds for plastic deep-drawn parts and foams.
- 2011
Initial certification of quality management to ISO 9001.
- 2018
Relocation to Wilnsdorf; overhaul of workflows and alignment with Industry 4.0.
- 2019
Awarded the Innovation Prize for Crafts NRW.
- 2024
Finalist and top 3 in the 'Excellence in Production' competition (external tool making with fewer than 50 employees category).