Design and manufacture of die-casting and injection moulds, deburring tools, fixtures as well as contract manufacturing
Willi Frehner AG
Oberbüren (CH)New on Amplifa
About Willi Frehner AG
Willi Frehner AG is a family-owned company based in Oberbüren (SG) that has specialised since 1980 in the design and manufacture of die-casting and injection moulds, deburring tools, machining fixtures and stamping tools. In die casting, complete solutions comprising die-casting die, deburring tool and machining fixture are delivered from a single source for aluminium, magnesium and zinc alloys; in injection moulding, hot-runner and cold-runner tools with up to 64 cavities are produced. Contract manufacturing serves customers from precision mechanics as well as machine and apparatus engineering with milling up to 5-axis simultaneous, EDM, grinding, turning and deep-hole drilling. Production takes place on a modern machine fleet from GF Machining Solutions (Mikron), AgieCharmilles, Fehlmann, Schaublin and Kellenberger. Every tool is sampled on a try-out press, checked with Mould Check and tested for leakage of the cooling circuits; in addition, the company offers revision, repair and conversion of new and third-party moulds. Around 1,000 m² of production space is available at the site on the ground floor of an own building with a photovoltaic system.
- Site
- Oberbüren
- Processes
- Die-casting dies (design & manufacture), Injection moulds (hot-runner and cold-runner tools up to 64 cavities), Deburring tools, Machining fixtures, Stamping tools, Soft and hard milling up to 5-axis simultaneous and 36'000 rpm, CNC turning, Wire EDM
- Materials
- Aluminium alloys (die casting), Magnesium alloys (die casting), Zinc alloys (die casting), Copper (electrodes for sinker EDM), Plastics (injection moulds), Aluminium alloys, Magnesium alloys, Zinc alloys
- Founded
- 1980
- Employees
- 20
- Industries
- Die casting, Plastics injection moulding, Automotive industry, Precision mechanics, Machine and apparatus engineering
- 01
Development and design (CAD/CAM Cimatron, Moldex3D)
- 02
Milling up to 5-axis simultaneous
- 03
EDM (sinker, wire, start-hole)
- 04
Turning
- 05
Grinding (surface, cylindrical, jig)
- 06
Deep-hole drilling
- 07
Assembly and fitting
- 08
Sampling and functional testing on try-out press
- 09
Mould Check and leak testing
- 10
Delivery; revision, repair and service
Materials and Processes
Aluminium alloys
Material for die-casting dies in the complete solutions from a single source.
Magnesium alloys
Material for die-casting dies.
Zinc alloys
Material for die-casting dies.
Plastics
Injection moulds with hot and cold runners up to 64 cavities.
Copper
Electrode material for sinker EDM.
Sites
Oberbüren
CHProduction and administration
- Materials
- Aluminium, magnesium, zinc, plastics, steel (tool steel), copper
- 5-axis milling machines Mikron Mill X600U (pallet changer), HPM800U, VCP800, VCP600, VCE1000, HEM1000
- Fehlmann P60
- Mikron WF 21/31/41
- Sinker EDM machines AgieCharmilles Form 3000 and Form X400 with WPT1+
- Wire EDM machines AgieCharmilles Cut P550 Uniqua and Charmilles 4020 SI
- Start-hole EDM machine AgieCharmilles Drill 20
- Lathes Schaublin 102N-VM, Feeler FTC10 CNC
- Surface, cylindrical and jig grinding machines Minini PL8, Elb, Kellenberger, Moore
- Wotan boring mill with deep-hole drilling kit
- 2 Reis try-out presses TUS 115-40
- CNC measuring machine Rapid Plus in a climate-controlled measuring room
- Hot-runner controller Husky Altanium 5 (Mould Check)
Tools and Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Die-casting dies (design & manufacture)Casting | – | – | – | – | Aluminium alloys, Magnesium alloys, Zinc alloys |
| Injection moulds (hot-runner and cold-runner tools up to 64 cavities)Plastics | – | – | – | – | Plastics |
| Deburring toolsTool making | – | – | – | – | – |
| Machining fixturesTool making | – | – | – | – | – |
| Stamping toolsTool making | – | – | – | – | – |
| Soft and hard milling up to 5-axis simultaneous and 36'000 rpmMachining | – | – | – | – | – |
| CNC turningMachining | – | 1000 mm (Ø 450 x 1'000) | – | – | – |
| Wire EDMMachining | RA 0.08 | 1'200 mm × 700 mm × 400 mm | 1'500 kg | – | – |
| Sinker EDMMachining | – | 1'200 mm × 800 mm × 350 mm | 2'000 kg | – | – |
| Start-hole EDMMachining | – | – | – | – | – |
| Surface grindingMachining | – | 1'300 mm × 750 mm × 800 mm | – | – | – |
| Cylindrical grindingMachining | – | 1'000 mm | – | – | – |
| Jig grindingMachining | – | 460 mm × 280 mm × 330 mm | – | – | – |
| Deep-hole drilling (single-lip drill)Machining | – | 1'000 mm × 1'000 mm × 800 mm | 2'000 kg | – | – |
| Tool acceptance / sampling on try-out press (tools up to 1'000 x 800 mm)Inspection | – | 1'000 mm × 800 mm | – | – | – |
| Functional testing / Mould Check / leak testing of cooling circuitsInspection | – | – | – | – | – |
| CNC measuring machine (target/actual comparison with CAD data)Inspection | – | 1'200 mm × 800 mm × 700 mm | – | – | – |
| Tool revision and repair service for die-casting and injection mouldsMaintenance | – | – | – | – | – |
| CAD/CAM design (Cimatron, Mastercam, Moldex3D)Engineering | – | – | – | – | – |
| Laser Cusing: additive manufacturing (with partners)Additive | – | – | – | – | – |
32 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| 5-axis milling machine with automated pallet changer | GF Machining Solutions (Mikron) Mill X600U | – | 800/600/500, 36'000 min-¹ | – | Oberbüren |
| 5-axis milling machine | GF Machining Solutions (Mikron) HPM800U | – | 800/800/550, 20'000 min-¹ | – | Oberbüren |
| Milling machine | GF Machining Solutions (Mikron) VCP800 | – | 800/600/550, 20'000 min-¹ | – | Oberbüren |
| Milling machine | GF Machining Solutions (Mikron) VCP600 | – | 600/500/550, 20'000 min-¹ | – | Oberbüren |
| Milling machine | GF Machining Solutions (Mikron) VCE1000 | – | 1'000/600/550, 10'000 min-¹ | – | Oberbüren |
| Milling machine | GF Machining Solutions (Mikron) HEM1000 | – | 1'000/600/550, 20'000 min-¹ | – | Oberbüren |
| Milling machine | Fehlmann P60 | – | – | – | Oberbüren |
| Milling machines | Mikron WF 21/31/41 | – | – | – | Oberbüren |
| Conventional milling machines | – | – | – | – | Oberbüren |
| Sinker EDM machine | AgieCharmilles Form 3000 | – | 600/400/500, 40-fold electrode changer, workpieces (1'200 x 800 x 350) up to 2'000 kg | – | Oberbüren |
| Sinker EDM machine | AgieCharmilles Form X400 with WPT1+ | – | 80 electrode positions, 9 pallet positions | – | Oberbüren |
| Wire EDM machine | Agie Charmilles Cut P550 Uniqua | – | 550/350/400, max. workpiece size 1'200 x 700 x 400, 1'500 kg, RA 0.08 | – | Oberbüren |
| Wire EDM machine | Charmilles 4020 SI | – | – | – | Oberbüren |
| Start-hole EDM machine (hole popper) | Agie Charmilles Drill 20 | – | – | – | Oberbüren |
| Lathe | Labor | – | Ø 450 x 1'000 | – | Oberbüren |
| Lathe | Schaublin | – | Ø 250 x 500 | – | Oberbüren |
| Lathe | Schaublin 102N-VM | – | Ø 200 x 500 | – | Oberbüren |
| CNC lathe | Feeler FTC10 | – | Ø 240 x 255, 6'000 min-¹ | – | Oberbüren |
| Surface grinding machine | Minini PL8 | – | 1300/750/800 | – | Oberbüren |
| Surface grinding machine | Elb | – | 600/350/300 | – | Oberbüren |
| Surface grinding machine with sine table | Elb | – | 500/250/300 | – | Oberbüren |
| Surface grinding machine | Elb | – | 400/200/200 | – | Oberbüren |
| Cylindrical grinding machine | Kellenberger 1000RJ | – | Ø 250 x 1000 | – | Oberbüren |
| Cylindrical grinding machine | Kellenberger 50HRJ | – | Ø 350 x 100 | – | Oberbüren |
| Jig grinding machine | Moore Conventional | – | 460/280/330 | – | Oberbüren |
| Boring mill with deep-hole drilling kit | Wotan | – | 1000/1000/800, rotary table 360°, 2'000 kg table load | – | Oberbüren |
| Try-out press | Reis TUS 115-40 | 2 | Clamping table 1'280 x 1'000, tools up to 1'000 x 800 mm | – | Oberbüren |
| CNC measuring machine | Rapid Plus | – | 800 x 1'200 x 700, EL,MPE = 1,9 + (L/350), climate-controlled measuring room, Renishaw 5-axis | – | Oberbüren |
| Hot-runner controller | Husky Altanium 5 (12 zones, Mould Check) | – | – | – | Oberbüren |
| Ultrasonic cleaning device | – | – | – | – | Oberbüren |
| Ultrasonic polishing device | – | – | – | – | Oberbüren |
| Leak testing device | – | – | – | – | Oberbüren |
Additional services
History
- 1980
Founding of Willi Frehner AG; over 40 years of know-how in mould and tool making