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CONTENTS5 Fichtner & Schicht GmbH – The shape of the future

7 Electroforming – The technological basis

9 Engineering and model making – Shaping ideas

TOOL TYPES – AREAS OF APPLICATION:

11 Assembly construction, steel construction and plant engineering

13 Spraying tools & silicone spraying tools

15 Slush tools with peripherals

17 Steering wheel foam moulds & injection moulding inserts

19 Special tool moulds and more

21 Quality management – Our pledge for more efficiency

23 Benefits – For the additional extra in tool making

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“Because the future needs a partner with ideas and commitment.” Jan Stricker, Managing Director technology

process from the start until delivery is checked in minute detail. We achieve real poten-

tial cost savings through our holistic service: model making according to customer-spe-

cific CAD data, electroforming and manual machining right through to the delivery of

the finished tool or the complete tool system for direct use in the production process.

And an additional benefit: we accompany the fitting of the tool in your production

facility guaranteeing a smooth SOP.

ON THE WAY TO ALL-IN-ONE-SOLUTION

The sign of good co-operation is when heads stay cool at crucial moments, when solu-

tions are found, and swift decisions are reached. In line with our corporate philosophy

we give a promise to the partners and employees of our company which is characteri-

zed by esteem, reliability, responsibility and team spirit: The best for the best – a quality

standard constantly being further developed.

Uniquely designed surfaces based on sophisticated tool moulds which make allowances

for the complex geometry of the part, guarantee high precision moulding and make an

impression with their durability and profitability. We can reflect on more than 4 deca-

des of sound and demanding workmanship in tool and mould making. At the same

time our indefatigable commitment ensures that we get the balance of innovation and

progress right in our workmanship. Besides nickel-based tool moulds for renowned

companies from the automotive industry we also make erosion protection profiles for

well-known companies in the aviation industry.

TECHNICAL PERFECTION WITH A HOLISTIC APPROACH

The core element and technological platform in this context is our electroforming pro-

cess with 30 nickel high- performance baths designed for more than 200 tool moulds of

various dimensions annually. Every enquiry undergoes a feasibility study and the whole

FICHTNER & SCHICHT GMBH – THE SHAPE OF THE FUTURE

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“The requirement profiles of our customers are the engine which drives us to highest performance.” Markus Tack, Managing Director Sales and Marketing

We give unique product designs a reproducible face – no ifs or buts. Our commitment

– even to render the most demanding of surface structures reproducible and profitable

– is the crucial characteristic that distinguishes our performance.

With our high-performance nickel baths, we shape nickel electrolytically on previous-

ly manufactured bath models. The thus created nickel shells are moulded extremely

precisely and achieve a layer thickness of 0.1mm up to many millimetres as well as a

separation efficiency of 25 to 50 mμ/h up to 1mm/h. The requirement profiles for our

tool moulds are varied and are a combination of complex geometries and unique grai-

ning (surface structures without separating edges) simultaneously with defined wall

thicknesses with maximum high lifetimes.

ELECTROFORMING – THE TECHNOLOGICAL BASIS

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The process stages in electroforming

The principle of electroforming

CAD data

leathermodel

siliconemould 1

master model

siliconemould 2

bath model

galvanic mould

nickel coating cathode

moulded part

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“Our way of thinking and doing is steered by absolute precision - uncompromisingly.” Thomas Döpel, Engineering

Every impulse and every idea captivate by precise and professional implementation.

This is a crucial aspect for the field of engineering and model making that we pursue

with every consequence.

It is already during the manufacture of our engineered master model, milled in 5 axes

with dimensions 3,000 x 1,600 mm - which we produce according to customer speci-

fic CAD data – that we focus on complete process transparency and cover all process

steps in-house. Our model making shop is responsible for the precision fit moulding

and likewise the necessary manual rework of the models. The smooth exchange of

data is guaranteed by our CAD system which is compatible with all common interfa-

ces. All manufactured models and stainless-steel stamps for E protection manufacture

undergo our strict quality control. Here we check the bath models optically and tacti-

lely before electroforming and compare the measurement values with the CAD data

ENGINEERING AND MODEL MAKING – SHAPING IDEAS

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supplied by the customer. All results are documented and handed to the customer as

a log. For more convenience we store your models for the lifetime.

Benefit from the additional extra in model making, we provide all services also as

single services:

- Milling as wage labour (all materials: model making materials, aluminium, steel) of

every kind

- Own production of rear assemblies for e.g. steering wheel foam tools

- Manufacturing of milled laminating facilities (also INVAR)

- Manufacturing of powder box adaptors out of cast aluminium with milled gasket

socket

- Classic tool making

With our customer specific assembly benches and workbenches, you achieve optimum processes in production.

Assembly facilities and workbenches

Our manufacturing facilities enable us to create safe, ergonomic workplaces for our

customers’ production workers. Our assembly facilities are equipped with sensor tech-

nology, which recognizes components (capacitively, inductively, optically), and a rota-

tion system for processing the component on both sides. Maximum process reliability

is achieved by visualizing operating instructions for the production workers. The addi-

tional extra in automation is attained by our assembly facilities with SPS control, ext-

raction devices, a RFID scanner for component recognition, an integrated screw system

including controlled torque, as well as individual manual tools or auxiliary tools. This

creates a significant advantage for our customers: higher efficiency and transparency

in processes.

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Steel construction and plant engineering

With our expertise in the field of steel construction and plant engineering we realize,

on customer request, customized facilities and we take over the metal construction.

Furthermore, we can take over responsibility for the design of welding or milling de-

sign as well as the individual manufacture of welded components from conventional

weldable materials.

PU spraying tool – independent tool system with integrated heating technology

Spraying tools & silicone spraying tools

With our spraying tool moulds we can manufacture PU spray skins for the demanding

surface designs of high-quality parts used later in automobile interiors. Special technical

finesse is required for manufacturing spraying tool moulds for dashboards with integra-

ted heating systems (electrical or water heating) and back lining. They are made with a

double coat of nickel – consisting of sulphamate nickel and solid nickel – and delivered

on the customer‘s request with back lining as a complete tool system. With our compo-

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sition of alloys, we can dispense with a third, additional coat of metal and therefore

enable our customers to achieve significant savings in materials at the same level of

quality and also the same long lifetime with excellent thermal stability. For urgent

cases we can offer our customers silicone spraying tools for manufacturing the first

parts before the start of series production.

Fine adjustment of the complete tool system.

Slush tools with peripheral equipment

To increase the variety of applications we develop slush tool moulds for the manufac-

ture of exclusive PVC slush skins for automobile interiors which excel in freedom of

design, weldability and soldering ability. Contrary to spraying tools, these tool moulds

are exposed to extreme stresses in the series process, for example alternating the heat

up to temperatures of around 300°C and subsequent cooling. Therefore, our enginee-

ring team attaches great importance to maximum durability with minimum wear. Our

holistic approach includes the coordination of the CAD data, the engineering and the

construction of customised models, the electroforming and the subsequent manual

machining right through to delivering a complete tool system as slush equipment (tool

frame, powder box, seal plate also out of aluminium, multicoloured masks).

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Flexible tool systems which adapt to produce accurate contours

The individual components are adapted to the individual contour of the slush tool

so that a contour-aligned gasket can be guaranteed. Depending on the field of use

we also manufacture the powder box and adapter plate in one element. These can

be made optionally from cast aluminium or steel or an aluminium-welding design.

Flexibility is a key priority for us: thus, with our expertise we can design and manu-

facture the tool systems for all known slush facilities on the market. For a smooth

start to SOP we coordinate the start-up of the tool with our customers.

Pure efficiency – turning old into new

And another plus: we re-engineer your existing slush tool systems so that they can

be used for many different types of facilities or other project applications. This ap-

plies to the re-use of slush equipment for other projects as well as for the modifica-

tion of existing slush tools on other types of facilities.

“At the beginning was the idea – today we are market leader for electroformed steering wheel foam moulds.” Manfred Klein, Technical Coordinator

Complete production of steering wheel foarm moulds with rear end

As a manufacturer of foam moulds for steering wheels and gear lever knobs we offer

our customers the realization of demanding, customer-specific design grains. With our

technical infrastructure for the complete production we can realize the model for electro-

forming from the customer-specific CAD data. This results in a nickel shell which is joined

to the customer-specific rear end, made optionally from steel or aluminium, which also

has an integrated heating system. Our composition of alloys guarantees high dimensional

tolerance, long service life and excellent demouldability of the tools.

Injection moulding inserts for the attention to detail

Whenever the completion of the interior design of automobiles with parts adjacent

to the dashboard is involved our vast expertise and attention to detail are in demand.

Here we join the customized rear end - optionally made out of steel or aluminium -

to a dabbed nickel galvano insert. The nickel shells have a wall thickness of 8 – 10

mm and are designed with zero supporting surface without cavities and intermediate

materials. That leads to a harmonious overall appearance of the surface design in the

automobile interior.

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Electroforming for highest standards

Special tool moulds and more

Our core competences in electroforming are supplemented wisely with further types of

tools and areas of know-how:

RIM/ROM tools for grained and ungrained interior and exterior parts incl. rear end,

foaming system, heating and cooling systems.

EDM-ELECTRODES for electric discharge technology for maximum exploitation in the

areas of surface optic and haptic.

SPECIAL TOOL MOULDS using electroforming for complicated surfaces e.g. parts with

microstructures, rotational moulding, tooth formation, city reliefs or tools for Fresnel

lenses for the solar industry.

LAMINATING FACILITIES for extensive tools in the autoclave process. On request with

individual rear end. From the design according to the customer’s data through to the

complete facility, ready for use in production. But we can do more: milling for the

creation of classic laminating tools (e.g. out of aluminium or INVAR) as well as the

manufacture of reusable silicone covers for laminating tools.

SELF-HEATING TOOLS are already equipped with an integrated surface heating

which heats the tool up evenly and consequentially saves the need for the autoclave

or tempering process.

The combination of different processes and technologies enables us to find inno-

vative and profitable solutions for our customers‘ individual ideas and requests.

No task is too demanding and no challenge too big. Furthermore, our customers

benefit from our service package which includes repairing galvanizing, milling on 5

axes, manual engraving, model making, repair work nationally and internationally

and laser welding.

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“Standard is not enough for us – we pursue highest quality benchmarks for more durability and efficiency.” Jan Stricker, Managing Director Technology

QUALITY MANAGEMENT – OUR PLEDGE FOR MORE EFFICIENCY

Sustainability and the challenge of consistent quality awareness is the maxim which we

pursue in every step of our work - uncompromisingly. Delivery quality is not only a sig-

nificant success factor for us but also for our customers. Parallel to our internal quality

guidelines we subject our performance to critical review in continuous intervals in order

to push optimisation ahead – for the highest level of customer satisfaction and for a sus-

tainable relationship of trust. We meet the challenges of the directive of ISO 9001:2015

and the aviation standard EN 9100:2018. Our expertise in quality management is not

only available as part of process support:

An Overview of our Service

– 3D scan using FaroArm

– Hardness testing

– Tensile testing

– ET/PT testing

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“Nobody can do everything, some can do something, together we will reach the goal.” Your contacts at Fichtner & Schicht

Grassroots company management – we are aware of our responsibility towards our

employees, customers and partners and manage our family business with greatest

care and foresight.

Further development – we invest continuously in our know-how and in our facility

technology.

Flexibility – we stand for fast decisions and flexible process adjustments when the

heat is on.

Convince yourself of our performance and become our partner!

Holistic approaches – we deliver from the coordination of the CAD data right through

to the finished tool, from one source. That saves time and costs and allows a high level

of control of the whole process.

Customer orientation – we accept our customers‘ challenges and have been realizing

them in reliable processes for over 40 years.

BENEFITS – FOR THE ADDITIONAL EXTRA IN TOOL MAKING

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A selection of our customers:

Fichtner & Schicht GmbH · Germaniastraße 4 · D-33189 SchlangenPhone: +49-5252-9354-0 · Fax: +49-5252-9354-54 · E-Mail: info@fi-sch.de · www.fi-sch.de