Innovative surface texturing technologies

With our innovative technologies we develop the ideal surface for our customers - competently, cost-effectively and time-saving. Modern methods of prototype modelling allow an exact and fast evaluation and selection of the suitable surface texture. On the basis of natural or artificial patterns, we realise the most diverse design ideas for you.

Laser technology

Endless diversity

Haptically and visually appealing surfaces for almost all types of plastic products:   The innovative 5-axis LaserTec process from Eschmann Textures uses laser ablation where a laser beam removes layer by layer from the tool surface of a plastic injection die. This produces multi-layered surface textures, ranging from complex architectural or geometric patterns to textile, natural patterns and fine textures. This method is also suitable for manufacturing functional surfaces such as for light reflection, friction, aerodynamics, etc.

Our team of specialists realises textures, engravings, micro textures, markings and inscriptions from 2D to complex 3D geometries in the shortest possible time.

Our laser technology centre in Wiehl can process tools with weights of up to 20 tonnes. We also offer 5-axis LaserTec services at our locations in France (Viry) and UK (Glossop) as well as worldwide with carefully selected project partners.

GET IN TOUCH!

You can download the LaserTec flyer here

LaserTec: at a glance

  • fully digital process chain with high repeatability
  • realistic 3D component texturing(mapping) in interaction with the user to optimally align the t surface texture
  • almost unlimited freedom of design
  • direct lasering of complex 3D textures
  • lasering and etching can be combined
  • suitable for steel, aluminium and – with some restrictions– for electrode materials (copper, graphite, tungsten)
  • ideal for technical applications such as ribs, honeycomb textures and fine lettering
  • high-precision five-axis processing with fibre laser

Go to our FAQs on laser technology

Go to our laser textures

You can download the laser data sheet here

5-axis fibre lasering P 4000 U: high-end technologies in new dimensions

  • pulsed, Ytterbium fibre laser for up to 20 tonnes work piece weight
  • very large working space for large-dimensional work pieces
  • various P series laser systems from GF Machining Solutions

LaserTec: the process sequence

  1. Inspiration
    Freedom of design through graphic development or by scanning templates and displaying them in greyscale.
  2. The basis – your tool data
    Identification of the areas of the texture based on the final tool data
    (.igs. /.stp / .catia)
  3. “Chess board” checker
    Identification of surface defects and optimisation of the texture in
    terms of size and development as a basis for 3D rendering
  4. 3D rendering – the virtual part
    Decision-making support for the end user using realistic graphic representation – also possible with colour gradations and shading.
  5. Tool mapping – and you’re good to go
    A negative texture based on the customer's approval as a basis for the laser process. Textures can also be positively lasered depending on the respective requirement.
  6. To the result...
    Process simulation after setting up the tool and 5-axis processing.

We would be pleased to advise you.

Direct Lasering

Complex technical, geometric textures are lasered directly onto the surface using greyscales to optimise their look and feel.

The greater the number of processing stages, the more sculptural the texture is.

Lasering + Etching

Graphics are lasered in paint and conventionally etched.

"Fit to form”: alignment of the texture and optimisation of properties over the complete die contour in close dialogue with the customer, if necessary.

 

 

Laser “Lite”

Matt-gloss effects can be achieved with a combination of high gloss and fine texture.

A depth effect can also be produced with effective shallow texture depth.

 

 

Laser “Brand”

Micro-decoration of tools: with (ultra-)fine texture, logos and lettering, technical textures, and more.

Also for functional surfaces.

 

Ceramic technologies

Cera-Shibo: Nothing is impossible

Greater design flexibility for plastic injection moulding: Eschmann Textures has an innovative technology – Cera-Shibo – that enables different designs to be produced from the same tool. In conventional production methods the tool determines how the stucture looks. Things are different with Cera-Shibo: By applying a heat-resistant, almost wear-free ceramic coating to the tool surface, plastic components can be produced in a very wide range of different looks. This provides you with a completely new level of flexibility that gives you an extra dimension of design creativity. Cera-Shibo adds a ceramic coating to create the surface texture.

Cera-Shibo enables users to enhance an almost infinite range of products by adding customised surface textures. This ceramic process facilitates true-to-original design reproduction at unbeatably short reproduction lead times. Cera-Shibo can be removed at any time from the tool without leaving residues and be re-applied without the need for additional polishing, modified wall thicknesses or similar.

Applications:

  • ranges from one-off custom designs to small batches
  • physical foaming (MuCell)
  • In-Mould Graining (IMG)
  • blow moulding
  • silicone moulding tools
  • PU foaming tools
  • expanded polypropylene processing (EPP)
  • plastic injection moulding (incl. polypropylene, PU etc.)

You can download the Cera-Shibo flyer here

Go to our ceramic textures


Cera-Mat:
Elegance you can see and feel

Cera-Mat is a flexible coating process in which microporous ceramic particles are applied to surfaces. This technology can significantly reduce shine to a nearly lacquer-like finish without changing the surface’s basic texture.
Cera-Mat can enhance or completely replace conventional gloss reduction processes such as Eschmann Textures’ MatDown. Tools coated with Cera-Mat are easy to protect from corrosion using a VCI powder. Use Cera-Mat to create elegant product finishes that look sophisticated and high-class.

Properties and benefits:

  • original equipment or optimisation of virtually all tool dimensions
  • short processing times
  • suitable for low layer thicknesses and low draft angles
  • low coating temperature means no thermal impairment of tool steel
  • coatings can be flexibly adjusted to fit the requirements of plastics. Possibility of graduated coating.
  • suitable for conventional cleaning agents and can easily be removed –
    there are hardly any limitations on repairs

You can download the Cera-Mat flyer here


Cera-Coat: Design flexibility & component optimisation

Based on the Cera-Shibo technology, Cera-Coat is a flexible surface finishing process for technical applications. CeraCoat develops its specific properties with high tensile strength under constant and controlled conditions during the tempering in a furnace. Cera-Coat is also useful for enabling the coating of B surfaces, e.g., to adjust wall thickness or rib contours, to improve filling characteristics and heat conduction, and consequently, to reduce costs where it counts.

Properties and benefits:

  • Cera-Coat can be polished (even up to mirror finishes)
  • the coating can be treated mechanically (e. g. milling, grinding, drilling)
  • coating thickness of greater than 300 μm is possible or also suitable for coating sintered or casting material
  • short processing times
  • low coating temperature means no thermal impairment of tool steel
  • tools can be restored to their original state at any time
  • flexible change management (e. g. subsequent rib reinforcement) and flexible repair of coating damage
  • improves die filling and surface quality of plastic parts (depending on the coating thickness and use of rigid/moveable tool sides)
GET IN TOUCH!

You can download the Cera-Coat flyer here

Etching technology

Expertise gained from decades of experience

Etching technology is a traditional craftsmanship used to apply textures to metal surfaces by means of chemical reaction. This technology is used in particular for the further treatment or finishing of plastic injection moulding dies made of steel or - to a limited extent - NF metals. Skilled craftsmanship, decades of experience as well as the ongoing development of the technology ensure that customers' design and functionality requirements are met.

Our customers can now select suitable surfaces from a wide range of patterns or develop individual textures based on these patterns. Our design & development department will support your ideas – from the initial design through to implementation. Prototypes or initial patterns visualise surface textures during the manufacturing process.

GET IN TOUCH!

 

Etching technology: at a glance

  • Ideal for large surfaces and simple geometries
  • Material removal by means of a chemical reaction (acids on metallic surfaces); areas not to be etched are accurately covered
  • Multi-layer etchings are feasible
  • Heavily dependent on the material (steel) used and the die contour
  • Structural limits in the die must be precisely defined
  • Requires polish grades of at least 320
  • Production-related tolerances of up to +/- 10 µm are required
  • Available worldwide

Go to our FAQs on etching technology

Go to our etching textures

 

 

Etching technology: the process sequence

  1. Customer support
    The first step is to consult the customer to clarify how the perfect surface should look and feel. Our design team develops surface textures according to customer requirements and recommends the most cost-effective production process
  2. Digital processing
    The chosen design is then digitalised by the graphic designer.
  3. Film printing
    After design digitalisation, the flexible carrier film is then printed with acid-resistant ink.
  4. Film application
    The printed design is then transferred from the film to a steel insert.
  5. Acid bath
    The insert is immersed in an acid bath for a defined period of time. The acid only reacts in areas where there is no ink. After exposure to the acid, the steel die is sand blasted to clean it.
  6. Inspection
    The first result is moulded and visually assessed...
  7. Measurement
    … as well as optically measured.
  8. Work piece cleaning
    The dies can be machined if the sample texture meets the customer's requirements.
  9. Masking
    Areas that are not to be machined are protected with special paint – so-called masking.
  10. Reworking of masking
    Edges and details of the masking must be carefully reworked.
  11. Retouching
    Distortions, coatings and similar are carefully retouched.
  12. Acid bath
    When retouching is complete, the die is placed in an acid bath for a defined period of time. After exposure to acid, the die is sand blasted to clean it.
  13. Taking a cast for testing
    An initial cast is used to test the texture.
  14. Inspection
    A visual inspection then follows…
  15. Measurement
    …and an optical measurement.
  16. Gloss level inspection
    The last step is to inspect the gloss level.

We would be pleased to advise you.

Materials expertise

The right material to guarantee the right quality

The selection of steel plays a decisive factor in achieving a perfect graining result. It is important to ensure that only steels are used that are suitable for graining. Pre-processing and heat treatment are of major importance for steel quality: A high purity factor with regard to oxides and sulphides, reduction in steel parasites, fine and uniform micro texture as well as little segregation within the steel lead to optimal graining results.

If plastic parts are joined together to make one unit, all the required dies need to be made from the same steel and undergo the same heat treatment. This reduces the risk of material-related deviations in relation to the gloss level, grain depth and quality.

We would be pleased to advise you!

High-grade plastic mould steel from EschmannStahl

Our affiliate company EschmannStahl GmbH & Co. KG offers an optimum choice of material from a wide range of products and industry know-how in the provision of tool and die making that it has built up over the decades.

In line with the motto "everything from a single source”, EschmannStahl also offers many different steel-related services.

ESCHMANNSTAHL – our best performer
ES Aktuell 1200

Outstanding grain properties
over the entire cross-section

  • very high thermal conductivity
  • very high tenacity
  • prehardened and tempered up to 1200 N/mm²
ES Primus

For greater production reliability and longer service life

  • higher tenacity
  • better thermal conductivity
  • improved wear resistance due to an increase in the hardness
  • good machinability
  • an isotropic texture can be achieved through a special hardening process
  • differing graining behaviour compared with ES Aktuell 1200 influenced by the material properties
ES Atlas 42

First-class special material

  • optimum polishing
  • higher tenacity for long service life
  • excellent wear resistance
  • uniform through hardening
  • high graining safety
  • higher thermal conductivity
ES Multiform SL

First-class, versatile,
high-quality – an
all-rounder for all areas!

  • homogeneous properties over the entire cross-section
  • excellent graining capability

The entire range of services can be found at: www.eschmannstahl.de/en/product-category/plastic-mould-steel-en/

 

CONTACT

Eschmann Textures International GmbH
Dieringhauser Straße 159
51645 Gummersbach
Germany

Phone +49 22 61 / 98 99 0

info@eschmanntextures.de