Manufacture of complex injection moulding tools (1K, 2K, 3K, LSR, insert) from design to final assembly
SAUR Werkzeugbau GmbH
Lauffen am NeckarNew on Amplifa
About SAUR Werkzeugbau
SAUR Werkzeugbau GmbH is a tool and mould making company founded in 1977 by Werner Saur, headquartered in Lauffen am Neckar. Its core competence is the development and manufacture of complex injection moulding tools, including 1K, 2K and 3K tools, LSR tools, insert tools, unscrewing tools and stack tools. The complete production of injection moulds takes place in-house: from consulting including injection moulding simulation (Moldex 3D) and 3D design (Solid Works) through to manufacturing and final assembly. Tools up to 800 mm × 800 mm and 3.0 t are produced, with larger builds realized together with partner companies. In addition to tool making, the company offers contract manufacturing services such as milling, turning, grinding, die sinking EDM and wire EDM. It serves industries such as the automotive, electrical and household appliance industries, sanitary engineering, medical technology, control, regulatory and metrology technology as well as consumer goods, cosmetics, construction, toys and the watch industry.
- Site
- Lauffen am Neckar
- Processes
- Manufacture of complex injection moulding tools (1K, 2K, 3K), LSR tools, Insert tools (insert technique), Unscrewing tools (unscrewing), Stack tools, Sheet metal overmoulding, Tool design (CAD) incl. simulation (Moldex 3D), Milling (contract manufacturing)
- Materials
- Tool steel (steel and electrodes, CAM programming), Thermoplastic, LSR (Liquid Silicone Rubber), Tool steel, Thermoplastics, Liquid Silicone Rubber (LSR)
- Certificates
- DIN EN ISO 9001, ISO 9001
- Founded
- 1977
- Industries
- Automotive industry, Electrical industry/microelectronics, Household appliance industry, Sanitary engineering, Control, regulatory and metrology technology, Medical technology
- 01
Consulting incl. injection moulding simulation (Moldex 3D)
- 02
Design (Solid Works 3D)
- 03
CAM programming
- 04
CNC manufacturing (milling, turning, grinding)
- 05
EDM (die sinking EDM, wire EDM)
- 06
Final assembly
- 07
Maintenance, repairs and modifications
Materials and processes
Tool steel
Main material for injection moulding tools, mould inserts and electrodes; CAM programming for steel and electrodes.
Thermoplastics
Class of plastics for which the manufactured tools are used in injection moulding production.
Liquid Silicone Rubber (LSR)
Liquid silicone for the special tools in LSR injection moulding.
Locations
Lauffen am Neckar
DEManufacturing hall and administration (Hoher Steg 4)
- Part weight / size
- Tools up to 3.0 t
- Materials
- Tool steel, thermoplastic, LSR
- DMG MORI DMC 85 Monoblock (940 × 850 mm, 3-fold pallet changer, 800 kg each)
- DMG MORI DMU 60 eVo (automated)
- 2× Exeron HSC 600
- OPS Ingersoll Gantry 500 / Gantry Eagle 500 / Eagle G80 Competition (die sinking EDM)
- Sodick ALC 600 G and SLC 600 C (wire EDM)
- Mitsubishi Start 43 (start hole drilling)
- Surface grinding machines Jung JF 520 / JF 415, Elb Perfekt 6 SPS-NK
- GDW C400Z CNC lathe
- Mitutoyo Quick Vision ACTIVE 404, Zeiss C400 (measuring technology)
- 6× Solid Works 2020 Professional, TopSolid V7, Esprit, PEPS, Multiprog, Moldex 3D
Components and tools
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of complex injection moulding tools (1K, 2K, 3K)Tool making | – | 800 mm × 800 mm | 3.0 t | – | – |
| LSR toolsTool making | – | – | – | – | – |
| Insert tools (insert technique)Tool making | – | – | – | – | sheet metal |
| Unscrewing tools (unscrewing)Tool making | – | – | – | – | – |
| Stack toolsTool making | – | – | – | – | – |
| Sheet metal overmouldingTool making | – | – | – | – | sheet metal |
| Tool design (CAD) incl. simulation (Moldex 3D)Engineering | – | – | – | – | – |
| Milling (contract manufacturing)Machining | – | 800 mm × 800 mm | 3.0 t | – | steel |
| Turning (contract manufacturing)Machining | – | – | – | – | steel |
| Grinding (contract manufacturing)Machining | – | – | – | – | steel |
| Die sinking EDM (contract manufacturing)Machining | – | – | – | – | steel |
| Wire EDM (contract manufacturing)Machining | – | – | – | – | steel |
| Final assembly of injection mouldsAssembly | – | – | – | – | – |
| Tool maintenance and repairTool making | – | – | – | – | – |
26 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Milling machine (monoblock, 3-fold pallet changer, 800 kg each) | DMG MORI DMC 85 Monoblock | 1 | 940 mm x 850 mm | – | Lauffen am Neckar |
| Universal machining centre, automated | DMG MORI DMU 60 eVo | 1 | 600/500/500 | – | Lauffen am Neckar |
| HSC milling machine (50-fold pallet changer for electrodes, 5-fold pallet changer | Exeron HSC 600 | 2 | 500 mm x 350 mm | – | Lauffen am Neckar |
| Conventional milling machines | Deckel | – | – | – | Lauffen am Neckar |
| CNC die sinking EDM machine | OPS Ingersoll Gantry 500 | 1 | 500 mm x 400 mm | – | Lauffen am Neckar |
| CNC die sinking EDM machine | OPS Ingersoll Gantry Eagle 500 | 1 | 500 mm x 400 mm | – | Lauffen am Neckar |
| CNC die sinking EDM machine | OPS Ingersoll Eagle G80 Competition | 1 | 850 mm x 550 mm | – | Lauffen am Neckar |
| Conventional EDM machines | Agie Puls | – | – | – | Lauffen am Neckar |
| Wire EDM machine | Sodick ALC 600 G | 1 | 400 mm x 250 mm | – | Lauffen am Neckar |
| Wire EDM machine | Sodick SLC 600 C | 1 | 600 mm x 400 mm | – | Lauffen am Neckar |
| Start hole drilling machine | Mitsubishi Start 43 | 1 | 450 x 300 mm | – | Lauffen am Neckar |
| Surface grinding machine | Jung JF 520 | 2 | – | – | Lauffen am Neckar |
| Surface grinding machine | Jung JF 415 | 1 | – | – | Lauffen am Neckar |
| Surface grinding machine | Elb Perfekt 6 SPS-NK | 1 | – | – | Lauffen am Neckar |
| CNC lathe (12-position turret) | GDW C400Z | 1 | – | – | Lauffen am Neckar |
| Multidimensional coordinate measuring machine (optical/multisensor) | Mitutoyo Quick Vision ACTIVE 404 | 1 | – | – | Lauffen am Neckar |
| Coordinate measuring machine | Zeiss C400 | 1 | – | – | Lauffen am Neckar |
| 3D measurement program directly on machine (Renishaw) | Renishaw | 2 | – | – | Lauffen am Neckar |
| CAD workstations (3D design) | Dassault Systèmes Solid Works 2020 Professional | 6 | – | – | Lauffen am Neckar |
| CAM programming workstations (steel and electrodes) | TopSolid V7 | 4 | – | – | Lauffen am Neckar |
| CAM programming workstation (wire EDM) | Esprit | 1 | – | – | Lauffen am Neckar |
| CAM programming workstation (wire EDM) | PEPS | 1 | – | – | Lauffen am Neckar |
| CAM programming workstation (die sinking EDM) | Multiprog Gantry | 1 | – | – | Lauffen am Neckar |
| CAM programming workstation (die sinking EDM) | Multiprog Eagle | 1 | – | – | Lauffen am Neckar |
| CAM programming workstation (die sinking EDM) | Eagle PowerSPARK | 1 | – | – | Lauffen am Neckar |
| Simulation software (injection moulding) | Moldex 3D | 1 | – | – | Lauffen am Neckar |
Additional services
Quality
SAUR Werkzeugbau GmbH has a quality management system aligned with tool and mould making in accordance with DIN EN ISO 9001. For measurement equipment monitoring and inspection, coordinate measuring machines from Zeiss and Mitutoyo as well as 3D measurement programs from Renishaw are used directly on the machines.
| Evidence | Lauffen am Neckar |
|---|---|
| ISO 9001 |
History
- 1977
Company founded by Werner Saur
- 2015
Marco Kroneis took on more responsibility as authorised officer (Prokurist)
- 2019
Marco Kroneis became managing director (managing partner)