Prototypes, toolmaking and small-series plastic injection molding, 3D printing and gauge building from Waltershausen
ModellTechnik Rapid Prototyping GmbH
WaltershausenNew on Amplifa
Prototyping from model to small series
ModellTechnik Rapid Prototyping GmbH in Waltershausen develops and manufactures design models, prototypes, pre-series and small-series parts as well as complex technical products. The service portfolio comprises more than 30 production processes: additive processes such as stereolithography (SLA), selective laser sintering (SLS) and metal laser sintering, vacuum casting, model building with CNC milling, and toolmaking for prototype, small-series and blow-molding tools. In its own injection molding technical center covering 1,300 m², components from 1 g to approx. 4 kg are produced, with clamping forces from 90 t to 2,000 t, including the MuCell process and back-molding of textiles and films. The material range extends from PP, PA, ABS and PPS to glass- and carbon-fiber-reinforced plastics as well as metals. In addition, the company offers finishing (laminating, painting, flocking, vapor metallization), gauge building with cubings and checking gauges, design using CATIA, Moldflow simulation and assembly of functional assemblies. On 10,000 m² of production space, MODELLTECHNIK supplies the automotive, aerospace, medical technology, mechanical engineering, design and rail transport sectors, among others serving Audi, Stihl, SCHICK and Jena-Optronik.
- Site
- Waltershausen
- Processes
- Stereolithography (SLA), Selective laser sintering (SLS), Metal Laser Sintering, 3D printing (various processes, more than 30 production processes), Vacuum Casting, Milling (model building, e.g. 1:1 body master model, milling center for gauges), Toolmaking – prototype tools (plastic injection molding), Toolmaking – small-series tools for injection molding
- Materials
- Polyamide (nylon), TPU (thermoplastic polyurethane), Polypropylene (PP), PA (polyamide, injection molding), ABS, PPS, Aluminum, Steel (non-hardened)
- Certificates
- DIN EN ISO 9001:2015, IATF 16949:2016, DIN EN ISO 14001:2015, DIN EN ISO 50001:2018, EN 9100:2018, TISAX
- Industries
- Automotive, Aerospace, Medical technology / dental, Industry / mechanical engineering, Design, Rail transport
- 01
Technical consulting
- 02
Component design (CATIA)
- 03
Moldflow and warpage calculations
- 04
Prototype building / rapid prototyping (SLA, SLS, milling, vacuum casting)
- 05
Toolmaking (prototype, small-series and blow-molding tools)
- 06
Injection molding in the technical center
- 07
Finishing (laminating, painting, flocking, vapor metallization, among others)
- 08
Gauge building and metrology
- 09
Assembly of functional assemblies
Materials and processes
Polypropylene (PP)
Standard thermoplastic processed by injection molding, up to engineering plastics such as PPS.
Polyamide (PA/nylon)
Used in injection molding and as SLS powder with high strength and chemical resistance.
ABS
Thermoplastic for housing and interior components in prototype tooling.
PPS
High-performance engineering plastic for demanding injection-molded components.
TPU (thermoplastic polyurethane)
Flexible, abrasion-resistant material for SLS parts with elasticity and shock absorption.
Glass- and carbon-fiber-reinforced plastics
Used in the SLS process for components with high strength and stiffness.
Aluminum
Material for prototype and small-series tools as well as cubings and gauges.
Steel / hardened tool steel
For small-series tools with higher requirements for durability and precision, also as hybrid tools.
Metals (laser sintering)
Additive manufacturing of intricate metal structures.
Leather and natural-fiber components
Used in hand and press laminating for high-quality surface design of interior parts.
Locations
Waltershausen
DEHeadquarters and production: model building, toolmaking, gauge building, injection molding technical center
- Part weight / size
- Injection molding 1 g – approx. 4 kg
- Lot size
- Prototype to small series (10 – 1,000 units prototype tooling; small series
- Materials
- PP, PA, ABS, PPS, TPU, fiber-reinforced plastics, aluminum, steel, metals (SLS)
- Injection molding machines 90 t to 2,000 t (clamping forces 900–20,000 kN)
- Coordinate measuring machine LH1512 (accuracy class premium)
- SLS system
- Milling center
- 2 paint booths
- Balancing machines for impellers
- Moisture measuring devices
- 3D scanning (GOM)
Components and products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Stereolithography (SLA)Additive | – | – | – | – | Resins (plastic) |
| Selective laser sintering (SLS)Additive | – | – | – | – | Polyamide (nylon), TPU (thermoplastic polyurethane), glass-fiber-reinforced plastics, carbon-fiber-reinforced plastics, various metals |
| Metal Laser SinteringAdditive | – | – | – | – | Metals |
| 3D printing (various processes, more than 30 production processes)Additive | – | – | – | – | Plastics, Metals |
| Vacuum CastingCasting | – | – | – | – | Plastics |
| Milling (model building, e.g. 1:1 body master model, milling center for gauges)Machining | – | – | – | – | Aluminum, Plastics, Model-building materials |
| Toolmaking – prototype tools (plastic injection molding)Engineering | – | – | – | 10 units – 1,000 units | Aluminum, non-hardened steel, hardened tool steel (inserts) |
| Toolmaking – small-series tools for injection moldingEngineering | – | – | – | several thousand parts | Aluminum, Steel, Hybrid tools |
| Toolmaking – blow-molding tools (blow molding process)Engineering | – | – | – | – | Plastics |
| Plastic injection molding (injection molding technical center)Plastics | – | – | 1 g – approx. 4 kg | – | Polypropylene (PP), PA, ABS, PPS, Thermoplastics, high-performance engineering plastics |
| Back-molding of textiles and filmsPlastics | – | – | – | – | Textiles, Films, Thermoplastics |
| MuCell process (foam injection molding)Plastics | – | – | – | – | Thermoplastics |
| Laminating (hand and press laminating)Surface | – | – | – | – | Plastics, Natural-fiber components, Leather |
| Priming and paintingSurface | – | – | – | – | Plastics, Metals |
| FlockingSurface | – | – | – | – | Plastics |
| Vapor metallization (PVD coating of plastics)Surface | – | – | – | – | Plastics |
| Tumble polishingSurface | – | – | – | – | Plastics, Metals |
| Chemical smoothingSurface | – | – | – | – | Plastics |
| MattingSurface | – | – | – | – | Metals, Plastics |
| AnodizingSurface | – | – | – | – | Aluminum |
| Bluing (browning)Surface | – | – | – | – | Steel, Metals |
| Electroplated nickel platingSurface | – | – | – | – | Metals, Plastics |
| Assembly of functional assemblies (including bonding)Assembly | – | – | – | – | Plastics, Metals |
| Gauge building (checking gauges, measuring fixtures, cubings, gauges, jigs)Testing | – | – | – | – | Aluminum, Plastics |
| Coordinate metrology (NC measuring machine, GOM 3D scan, optical measurement)Testing | – | – | – | – | – |
| Moldflow simulation and warpage calculationsEngineering | – | – | – | – | Plastics |
| CAD part bulging (warpage compensation)Engineering | – | – | – | – | Plastics |
| Component design/developmentEngineering | – | – | – | – | Plastics |
| Heat treatment/tool shrinking (adjusting and measuring device with integrated tool shrinking system)Heat treatment | – | – | – | – | Tool steel |
12 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Injection molding machines (clamping forces 900 kN – 20,000 kN) | – | – | – | – | Waltershausen |
| Injection molding machine 90 t | – | – | – | – | Waltershausen |
| Injection molding machine 200 t | – | – | – | – | Waltershausen |
| Injection molding machine 400 t | – | – | – | – | Waltershausen |
| Injection molding machine 1,000 t | – | – | – | – | Waltershausen |
| Injection molding machine 2,000 t | – | – | – | – | Waltershausen |
| Coordinate measuring machine type LH1512 (accuracy class premium) | LH1512 | – | large-format components | – | Waltershausen |
| Paint booths | – | 2 | – | – | Waltershausen |
| Milling center | – | – | – | – | Waltershausen |
| SLS system | – | – | – | – | Waltershausen |
| Balancing machines for impellers | – | – | – | – | Waltershausen |
| Moisture measuring devices | – | – | – | – | Waltershausen |
Additional services
Reference customers
Quality and certifications
The quality management system certified since 1997 covers FMEA, gauge planning, sample submission, IMDS and complaint management according to a zero-defect strategy. The metrology includes a coordinate measuring machine LH1512 (accuracy class premium) for large-format components, GOM 3D scans and optical measurement at the customer's site.
| Evidence | Waltershausen |
|---|---|
| DIN EN ISO 9001:2015 | |
| IATF 16949:2016 | |
| DIN EN ISO 14001:2015 | |
| DIN EN ISO 50001:2018 | |
| EN 9100:2018 | |
| TISAX |
Company history
- 1997
Initial certification of the quality management system
- 2022
Expansion of the management system to include DIN EN ISO 14001:2015 and DIN EN ISO 50001:2018
- 2026
Thomas Näther becomes second managing director as of 01.04.2026; long-term safeguarding of the Waltershausen site
- 2026
InSuM Tech Day in Wolfsburg (27–29.10.2026) with 50 companies and research institutions, focus on vehicle interior