Plastic fantastic

NEFF's ovens and hobs, manufactured in Bretten near Pforzheim in Germany, have been admired for generations. To maintain this reputation, designers are looking for the very best in functionality, quality and durability for every new concept. With Proto Labs, this is faster and easier than ever. Bearing in mind the tough demands made on materials, the latest developments from Neff in the field of plastics are right at the cutting edge. Plastic is now being used in places that were previously 'metal only'. The guide rails of the fully retractable 'Hide'® oven door, which are built underneath the appliance, are now made from this flexible material. Does that mean a step backwards in terms of quality? "It's the exact opposite actually" according to Martin Brunner, who is responsible for construction for various categories of appliance and for the development of functional mechanical systems. "Modern plastics can offer a huge range of shapes, colours and surfaces. Working with various additives, extraordinary levels of strength, heat resistance and toughness can be achieved. We can also create lightweight shapes with specific features, which we can not do with metal. So we get less weight with more functionality and better design. The advantages of plastic in the finished product are very clear. Once the use of plastic has been introduced into series production, everything runs smoothly and all the advantages come to the fore. However, how to get the product ready for series production remains a challenge. Good preparation starts with choosing the right material and continues with making a tool which is suitable for manufacturing with plastic. The part must be constructed in a such a way that the material can be injected uniformly into the mould during production and the part can be ejected cleanly on opening. Due to the huge cost of tooling, the design for series production must be perfect. Making changes after the event is costly and time-consuming. This why the process used to be correspondingly laborious and and risky. All this has been turned on its head with Proto Labs and the rapid injection moulding service Protomold®. The process is simple: The data from simulation calculations from 3D modelling are uploaded to the Proto Labs quote platform "ProtoQuote" and an analysis of a production-compatible construction of the design and a firm quote for producing the parts in the plastic material of the client's choice is then produced in just one day. A few days later, the parts are delivered. In the case of new parts for the 'Hide' oven doors, quality testing led to various changes and adjustments. This was not a problem, as Martin Brunner points out: "Using Proto Labs' speedy service, with components in production material ready and delivered, we are now in the very comfortable position of being able to go though several amendment cycles in a short time. So we have arrived at the optimal production part quickly. Previously we needed three months for an auxiliary tool alone. With Proto Labs, we had the finished parts in our hands in 15 days, and it could have been even quicker with their express service. We have gained some very valuable development time" . He continues: Protomold's rapid injection moulding service has now become an integral part of Neff's product development. With Proto Labs, we have gained new insights into the development process and these will influence our processes into the future.