Ensinger Germany Ensinger worldwide

Ensinger GmbH Austria Italy Sweden Rudolf-Diesel-Straße 8 Ensinger Sintimid GmbH Ensinger Italia S.r.l. Ensinger Sweden AB 71154 Nufringen Werkstraße 3 Via Franco Tosi 1/3 Box 185 Tel. +49 7032 819 0 4860 Lenzing 20020 Olcella di Busto Kvartsgatan 2C Fax +49 7032 819 100 Tel. +43 7672 7012800 Garolfo 74523 Enköping www.ensinger-online.com Fax +43 7672 96865 Tel. +39 0331 568348 Tel. +46 171 477051 www.ensinger-sintimid.at Fax +39 0331 567822 Fax +46 171 440418 Ensinger GmbH www.ensinger.it www.ensinger.se Mercedesstraße 21 Brazil 72108 Rottenburg a. N. Ensinger Indústria de Japan United Kingdom Tel. +49 7457 9467 0 Plásticos Técnicos Ltda. Ensinger Japan Co., Ltd. Ensinger Limited Fax +49 7457 9467 100 Av. São Borja 3185 Shibakoen Denki Bldg. 7F Wilfried Way www.ensinger-online.com 93.032-000 São Leopoldo-RS 1-1-12, Shibakoen, Minato-ku Tonyrefail Tel. +55 51 35798800 Tokyo 105-0011 Mid Glam CF39 8JQ Ensinger GmbH Fax +55 51 35882804 Tel. +81 3 5402 4491 Tel. +44 1443 678400 Wilfried-Ensinger-Straße 1 www.ensinger.com.br Fax +81 3 5402 4492 Fax +44 1443 675777 93413 Cham www.ensinger.jp www.ensinger.ltd.uk Tel. +49 9971 396 0 China Fax +49 9971 396 570 Ensinger (China) Co., Ltd. Poland USA www.ensinger-online.com Rm 2708.27 / F Ensinger Polska Sp. z o.o. Ensinger Inc. Nanzheng building No. 580 ul. Spóldzielcza 2a 365 Meadowlands Boulevard Ensinger GmbH Nanjing Road (W) 64-100 Leszno Washington, PA 15301 Borsigstraße 7 Shanghai 200041 Tel. +48 65 5295810 Tel. +1 724 746 6050 59609 Anröchte Tel. +86 21 52285111 Fax +48 65 5295811 Fax +1 724 746 9209 Tel. +49 2947 9722 0 Fax +86 21 52285222 www.ensinger.pl [email protected] Fax +49 2947 9722 77 www.ensinger-china.com www.ensinger-online.com Singapore Czech Republic Ensinger International GmbH Ensinger GmbH Ensinger s.r.o. (Singapore Branch) Mooswiesen 13 Prùmyslová 991 63 Hillview Avenue # 04-07 88214 Ravensburg P.O. Box 15 Lam Soon Industrial Building Tel. +49 751 35452 0 33441 Dobøany Singapore 669569 Fax +49 751 35452 22 Tel. +420 37 7972056 Tel. +65 65524177 www.thermix.de Fax +420 37 7972059 Fax +65 65525177 www.ensinger.cz [email protected]

France Spain Ensinger France S.A.R.L. Ensinger S.A. ZAC les Batterses Girona, 21-27 ZI Nord 08120 La Llagosta 01700 Beynost Barcelona Tel. +33 4 78553635 Tel. +34 93 5745726 Fax +33 4 78556841 Fax +34 93 5742730 www.ensinger.fr www.ensinger-plastics.com

Thermoplastic engineering and high-performance plastics from Ensinger are used in almost every important sector of industry today. Their economic efficiency and performance benefits have seen them

frequently supplant classically used materials. 27 E9911075I002GB 10/10

www.ensinger-online.com

Engineering plastics Facts and figures

Headquarters Products Nufringen, Germany • Compounds • Stock shapes

Workforce (extruded, cast, sintered) approx. 1,800 • Profiles Year founded • Finished parts 1966 (machined, injection moulded) • Custom castings Production sites in Germany (direct formed, cast ) 3 Applications in the sectors Locations and branches • Mechanical and plant worldwide engineering 25 • Construction industry • Automotive engineering Managing Directors • Medical technology Klaus Ensinger, Dr. Roland Reber • Aerospace industry • Oil and gas industry • Electrical and semiconductor engineering • and many other sectors of industry

2 We are fascinated by engineering plastics. We work day to day in our locations across Europe, the USA, South America and Asia to ensure the successful application of these modern materials.

Whether compounds, stock shapes, profiles or finished parts – Ensinger products play an essential role in ensuring more efficient and consequently more competitive applications for our customers. We achieve this through critical scrutiny and by keeping a close ear to the ground – because it is only with a thorough understanding of problem issues that solutions can be developed which really address market needs. Pacemakers for innovation

New and improved materials provide a vital driving force for technological progress. Plastics have a whole array of benefits to offer and in many cases can effectively replace materials or ceramics. And what’s more: They often provide the only alternative when it comes to the implementation of unusual technical applications. Which makes them a true pacemaker for innovation.

We process a comprehensive range of plastics Other important benefits include radiation and modifications to produce our compounds, resistance, excellent fire resistance and good stock shapes, precision profiles and finished electrical properties. Using special additives, parts. Our work focuses particularly on tem- thermal dimensional stability and rigidity can perature-resistant high-performance and engi- be enhanced, tribology improved, or electrical neering plastics. conductivity adjusted.

High-performance plastics Engineering plastics The success achieved by high-performance Engineering plastics can be used continuously plastics is based on a combination of material at temperatures between 100 °C and 150 °C. benefits which are brought to bear even at (PA), polyacetals (POM) and poly- raised temperature levels. These include, in ethylenterephthalates (PET) which also belong particular, good mechanical properties sup- to this group are referred to as technical ther- ported by extreme chemical resistance. The moplastics. These materials demonstrate good long-term service temperatures achieved by mechanical characteristics and a high degree materials such as PEEK, PPS and PSU are of chemical and wear resistance. They also between 160 and 260 °C. will not offer easy machining properties. melt or soften even when heated briefly to as high as 350 °C. Standard plastics This category includes polyolefines such as PMP, PP and PE. These materials offer an ideal characteristic profile for a wide range of standard requirements in the temperature range up to 100 °C.

4 TECASINT Polyimid (PI)

TECAPEEK Polyetheretherketon (PEEK)

Profiles

Compounds Stock Shapes

Chemistry Market

TECAMID Cast Nylon Polyamid (PA6, PA66)

Machined Parts

Direct Forming

From compounding through to application Our value chain is tailored to the demands of the market.

TECAFORM Polyacetal (POM-C, POM-H)

5 Application advice Distribution network Order and delivery service Service excellence starts with An efficient system of stock The stock shapes division is also comprehensive technical support. management ensures that our expanding its internet-based Precisely aligned to your branches and trading partners service on the Ensinger website. requirement profile, our experts receive all their deliveries – Convenient calculation and will find the most suitable whether extremely high quanti- purchase order tools can be material and the right production ties or special one-off supplies – accessed to maximize the ease technology for your needs. within the shortest possible delay and speed of order placement. or else “just in time”. Which gives you the assurance that you can plan safely and be sure of receiving your plastics just when you need them.

6 A solid foundation for quality products

Stock shapes made of engineering plastics Our stock shapes are cut and machined to in- form the basis for a wide range of new uses. dividual customer order with close tolerances The application scope is extensive and cus- guaranteed. Finished part manufacturers who tomer requirements are varied. Ensinger offers require only minimal quantities of stock extruded round rods, sheets and tubes in a shapes for a small production run or to pro- wide range of dimensions and colours. duce a prototype derive just as much benefit from our cutting and surface machining ser- We keep a permanent stock of popularly used vices as do large-scale buyers. By planing, high-temperature and engineering plastics grinding and contour planing we are able to always on hand in our European warehouse achieve wide-ranging high-precision solutions. in Nufringen. We also manufacture semi- finished products specifically to customer -or And our customers may rest easy in the assur- der. Where existing materials do not match the ance of compliance with stringent quality requirement profile, our compounders and standards every time. Strict guidelines and the process technicians work in close co-operation deployment of a skilled workforce safeguard with customers to develop new formulations. the individual process steps from incoming raw materials right through to the finished product.

7 Perfect insulation for frames and glazing

insulbar® insulation profiles for Thermix® TX.N® spacers and metal windows, metal doors and facades Thermix® muntin bars for double glazing

Ensinger is one of the world's leading develop- The product range Thermix® TX.N® is the cul- ers and producers of thermal insulation pro- mination of over 15 years spent in the develop- files for windows, doors and facades. insulbar® ment, production and application of spacers profiles achieve thermal separation of the and over 40 years of experience in high-perfor- inner and outer shells of metal frames. mance plastics. Thermix® “warm edge” spac- ers bridge the thermal gap which occurs at the More than almost any other Ensinger product, transition from glass to frame. By preventing insulbar® stands for sustainability. And has condensation and mildew at the glass edge, done so for over thirty years. The profiles Thermix® makes a major contribution to a improve insulation and make a major contri- healthy room climate. Windows stay dry. bution toward maintaining an optimum room climate. The positive environmental impact is Thermix® muntin bars lend the optical im- not just down to the marked reduction in pression of a conventional muntin window energy costs, but also the extreme durability of with glazing bars. The integrated bar profiles our profiles, which will survive the complete correspond in terms of both their design and life cycle of windows and facades. This saves function with the Thermix® TX.N® spacers resources in production and minimizes main- and are not in direct contact with the glass tenance costs. surface. Configured as rectangular hollow chamber profiles, Thermix® muntin bars are far easier to process than any duplex solution using spacer profiles.

As well as offering added convenience, our spacers also pay dividends in terms of saved energy costs. The use of Thermix® TX.N® also reduces the necessary energy required for air conditioning in summer.

8 From the vision through to production and logistics. One of Tested safety, reliable quality application: 360° support the methods used in developing Before any components under Each individual aspect of any the perfect insulbar® design development are used, they are project is part of a greater whole is finite element calculation to subjected to stringent testing and can be decisive to success. determine thermal transmission and controls. Only products which No matter whether customers coefficients precisely in line with have proven their quality in opt for a profile from the individual customer specifica- practical application are admitted standard range or require a tions. High process transparency into the standard range. Ongoing, bespoke new development. Our and efficiency lay the foundation state-of-the-art testing and specialists will be there to guide for optimum control of this inspection methods – also in the you through every step of the project. form of in-process testing – way: from advice on the most provide the assurance that our suitable materials, to develop- customers will receive precisely ment and design through to the product they envisage.

9 Precision for small production runs

Machining is the fastest, most economical The technological facilities include CNC mill- way to create a finished plastic component. ing machines (5-axis machining centres), Particularly when it comes to small production lathes with sub-spindles, driven tooling and a runs. In this field, Ensinger can provide a com- cleanroom. For processing high-grade fin- plete production service for your precision ished parts, tempering ovens are available in components, systems and assemblies. our factory which lend the material an even, stress-relieved structure. The company is able to draw on decades of experience in the machining of engineering In-process records, documentation and batch and high-temperature plastics. In our Cham traceability are essential pillars of our quality location, our highly skilled engineers produce assurance system. For projects in the medical precision components to the very narrowest technology and pharmaceutical fields, we also tolerances. The Sales Department assumes an perform biocompatibility tests. In addition to important service function, providing custom- standard audits, our operations are regularly ers with advice and support – also on their own audited by our customers. premises – in the selection of suitable materi- als and the design of finished parts.

Quality assurance in the machined finished parts division. Working in the background: Alois Haimerl, co-ordinate measurement technician

10 Efficiency and security

Our state-of-the-art injection moulding plant Above and beyond certification to DIN EN ISO in Rottenburg-Ergenzingen produces sophis­ 9001, we are also geared to various sector- ticated precision components and complete specific requirements. Our processes are de- assemblies using our entire range of high- signed in line with the automotive standard performance plastics and individually tailored ISO / TS 16949 and the standard governing filled compounds. medical devices DIN EN ISO 13485, as well as the requirements imposed by the aerospace From the initial idea through to the volume industry. We confirm our adherence to these production stage, the individual requirements standards by internal and external audits and of our customers form the focus of all our strive to continuously further improve our actions. Our engineers offer you their support work procedures. in the selection of materials and offer a pre- cisely tailored, economical solution – no mat- Because the components we produce are fre- ter what the application. quently required to guarantee elementary and safety-relevant functions, we impose the most Using an optimized material flow concept, the stringent requirements in terms of quality and injection moulding factory is ideally designed use automated test methods such as industrial for the efficient volume production of preci- image processing. Zero defects production is sion components. the benchmark we aspire to.

11 Formulations A high profile for success the world over

Ensinger develops and produces high-perfor- Experienced in the extrusion of mance compounds which can be optimized in for more than 40 years, the Industrial Profiles line with specific customer requirements with and Tubes division carries out projects and case the aid of fillers and additives. studies in co-operation with customers.

The new building completed in 2009 in the To meet customers’ requirements the technol- company's Nufringen location is home to one ogy of profile and pipe extrusion, as well as co- of Europe's most modern and flexible com- extrusion of different thermoplastics, can be pounding operations. Whether individual for- completed by inline or offline processes such mulations for customer developments or tried as printing and knurling, winding or cutting to and tested granulates from our standard range, size, thermoforming and welding, annealing whether materials for small production runs and conditioning. Our technology, expertise or mass manufacture – at Ensinger everything and more than 20 different thermoplastics comes from a single reliable source, whether modified by reinforcement, wear and friction products with improved sliding friction values, reducing additives and colour pigments were materials with defined electrical properties or essential for many successful applications and compounds used in medical applications. case studies for medical equipment, control A cleanroom is available for the production of engineering, the aircraft industry, electronics, materials which are required to comply with and engineering. special requirements.

12 Format for large-scale Withstanding high assignments levels of stress

Pressureless custom casting has proven a par- The high-temperature polyamides of the ticularly successful method for the production TECASINT range are the ideal materials to of bulky thick-walled components. Polyamide cope with tough application conditions. The finished parts and stock shapes manufactured broad temperature application spectrum of at the Cham location comply with extreme these sintered materials ranges from –270 °C loading, reliability and safety requirements to 300 °C. The materials will not melt, even if even under the most extreme conditions. exposed to temperatures of 350 °C for short periods. Strength, dimensional stability and The TECARIM casting process permits so- creep strength remain high under mechanical phisticated custom castings with different wall stress even during long-term usage. thicknesses. The stress-relieved semi-finished product TECAST offers excellent machining These pressed or machined finished parts and properties. Heavy-duty applications such as semi-finished products offer a high modulus pulleys, sliding elements and support plates and exceptional long-term thermal stability. for elevators, cable cars and cranes benefit Other benefits of our polyimides include a from the particular strengths of these materi- high level of purity and low outgassing, as well als: Abrasion resistance, light weight and cor- as excellent tribological properties even in dry rosion resistance. running applications.

Christian Rückerl, plant and machine operator, Cast Nylon division

13 Pioneering solutions

Over the years, Ensinger has gradually opened In addition, plastics are proving highly up exciting new fields of application for engi- successful for use in X-ray machines, com­ neering plastics which were formerly reserved puter and NMR tomography, blood analysis to metals and ceramics. Our products are now equipment and other imaging techniques due used not only in car clutches, gearboxes and to their transparency and resistance to electro- engine block covers: Many of the bearings, magnetic waves. bushes, levers and gears used in modern machine engineering are also made from The use of renewable energy sources is also high-performance plastics. Materials from not possible without innovative materials. Ensinger also help to enhance the speed and High-performance plastics are gaining in- safety of food production and packaging. Even creasingly in significance in applications to in medical and dental technology, polymers improve the efficiency of existing solutions. are encroaching on many of the applications In the field of energy saving, probably the formerly performed by metals. Lightweight most important means of saving precious instrument handles made of sterilizable plas- resources, Ensinger has for decades made a tics are only one example of many surgical vital contribution through the development applications which now make use of Ensinger and manufacture of thermal insulating products. profiles and spacers used in double glazing.

• Thermix® TX.N® spacers • insulbar® insulation profiles

• Higher surface temperatures • Comprehensive standard range on room-side glass edge • High precision and narrow (“warm edge”) tolerances guarantee reliable • Environmental protection: handling during assembly Lower heat losses mean reduced • Good thermal insulating

CO2 emissions properties • For all popular insulating glass products

14 Mechanical engineering Medicine / pharmaceuticals Thermal stability, resistance to chemicals and High-performance plastics from Ensinger are dimensional stability are only some of the produced from raw materials conforming to properties which are vital to the field of me- stringent FDA requirements, and are addition- chanical and plant engineering. Ensinger of- ally tested in their semi-finished state for bio- fers a wide portfolio of tribologically optimized compatibility to ISO 10993 at regular intervals. materials to address extreme wear resistance Plastics complying to the biocompatibility re- demands. These sliding friction-modified plas- quirements of USP Class VI are also available. tics are ideally suited for use in dry running The demands made on quality, product docu- applications under extreme conditions. mentation and product approvals are particu- larly stringent in the field of medical technol- Construction industry ogy. Ensinger is certified in compliance with insulbar® thermal insulation profiles for metal DIN EN ISO 13485. For our customers, using windows, metal doors and facades ensure pre-tested materials simplifies the process of highly efficient insulation. Thermix® spacers obtaining approvals for their own medical sever the thermal bridge which occurs at the technology products. By ensuring consistent transition from glass to frame in windows and documentation of individual process steps, facades. seamless product traceability is assured at Ensinger.

• Test socket for chips • Deflector • Output pulley • Snap contact (test adapter) for computer tomograph for luggage compartment TECAPEEK CMF (PEEK) TECAPEEK MT (PEEK) TECAPEI GF 30 mod (PEI) TECATRON GF 40 (PPS) Machining Injection moulding / machining Injection moulding Machining • Excellent hardness and rigidity • Application imposes stringent • Very high mechanical strength • Fibre-reinforced plastic • Excellent dimensional stability demands on materials and rigidity • 176 boreholes, • High abrasion resistance and processing methods • Creep strength over a wide narrow tolerances • Good electrical insulation • Radiation resistant temperature range • Excellent electrical properties • Long-term service temperature • High dimensional stability • Extremely abrasion resistant of 260 °C • Inherently flame resistant • High chemical resistance

15 • Friction pad for ski lift • Rack/shaft for • Sealing rings for the automatic transmission automotive industry TECARIM (PA6G) TECAMID 66 CF, TECASINT (PI) TECAMID 66 GF TF Custom casting Compression moulding (PA66 CF, PA66 GF TF) (direct forming) • Good abrasion and Injection moulding wear resistance • For long-term service • Extremely high impact strength, • Good sliding properties temperature ranges of –270 °C also down to –40 °C also in dry running applications to +300 °C • Good dry running properties • Good mechanical strength • Resistant to permanent • Low stress levels, warp-free • High impact strength deformation due to high degree • Good damping properties of elasticity • Good abrasion resistance

16 Automotive engineering Electronics Ensinger offers low-wear plastics for use in the Whether high precision, extremes of tempera- automotive engineering industry which are ture, electrical insulation, static proofing or temperature, fuel and oil-resistant and also defined electrical conductivity: Ensinger sup- comply with the stringent production and plies the electronics industry with materials to volume requirements imposed by the industry comply with the most demanding applica- in compliance with VDA standards. tions, hand in hand with effective volume pro- Our core expertise includes the production of duction methods such as injection moulding. between just a few hundred to several million precision components using single or multi- Semi-conductor technology ple component injection moulding. The pro- Many of the process steps involved in semi- duction processes we use comply with auto- conductor production call for handling compo- motive standard ISO / TS 16949 and in the nents made of qualified materials. Before any majority of cases are fully automated. plastic can be approved for cleanroom produc- tion, it must comply with stringent demands Aerospace within the framework of suitability tests. Vital Weight saving, high efficiency and no-compro- to the successful application of our materials mise reliability: These are the decisive factors in this sector are their low weight, chemical when it comes to plastics for the aerospace resistance, good dimensional stability, mini- industry. Providing an ideal alternative to met- mal outgassing and high material purity. als and glass, high-performance plastics from Ensinger have some impressive properties to offer: Minimal density coupled with high thermal and mechanical loading capacity, corrosion resistance and self-extinguishing properties.

• Deflecting pulleys for lifts • GPS transducer (position sensor) TECAST mod. (PA6G) TECATRON GF 40 (PPS) Custom casting Extrusion (industrial profile) • 7� lighter than pulleys made • Low coefficient of thermal from grey cast iron expansion • Lower centrifugal mass reduces • Very high strength and rigidity the inertia of the complete • High thermal stability installation • Excellent electrical properties • Resistant to corrosion • Low water absorption • Rope service life is increased due to low modulus of elasticity

17 from left to right: Hans-Martin König, Project Management, Injection Moulding Nina Finkbeiner, Product Management (High-performance plastics), Stock Shapes and Stefan Maag, Head of Internal Sales Germany, Stock Shapes Milena Müller, Quality Assurance (Series measurements), Injection Moulding

18 Ask. Think. Succeed.

Technically sophisticated bespoke solutions are not something you can simply take off a shelf. It is only by gaining a thorough initial understanding of the terms of reference, the application conditions and the requirements imposed on a precision plastic component that it is possible to develop a suitable suggestion.

Tuned precisely to your complete requirement We are also committed to providing compre- profile, our consultant engineers will find the hensive product compliance management. most suitable material and the right produc- National and international statutory require- tion technology for your needs. The flexibility ments create the framework for defining the of these high grade materials is matched physiological harmlessness and environmen- by the individual attention given by our spe- tal compatibility of materials. Adherence to cialists to the needs and preferences of our legal stipulations and material purity are of customers. Addressing their needs is both a extreme importance when it comes to applica- commitment and a challenge. With our wide- tions such as medical technology, food pro- ranging portfolio of products, production tech- cessing and drinking water contact. Our ex- niques, materials and services, it is a challenge perts provide the information that customers we are ideally equipped to face. need to ensure reliable approval of their end products.

19 Innovation born of continuity

We encourage our workforce to move away from well-trodden thought paths and to think outside the box. We welcome lateral thinkers, who often succeed in making the apparently impossible possible. Their independent initia- tive is an essential aspect of our ability to fulfil the wide-ranging demands of our customers.

But a sharp eye is essential to ensure the efficiency of internal procedures too. Here, we rely not only on the services of external audi- tors: Our own employees continuously moni- tor and optimize processes in the producing divisions and offices within the framework of the Ensinger continual improvement tool (EVI) for optimum productivity and quality assurance.

Impressive new developments are often an accumulation of countless minor improvements. But they certainly do not happen by chance. Behind every successfully implemented new development is a team of experts who can call on long years of experience combined with a lively sense of curiosity. We create the basis for this solid bedrock of expertise with our training program for the up-and-coming generation of young employees entering the company.

20 from left to right: Klaus Pascher, Sales Manager, Machined Parts Anika Harbord, Development Engineer, Compounds Sven Pflumm, Design Engineer, Injection Moulding Jürgen Haase, Shift Leader, Extrusion and Diogenis Vavulidis, Extrusion Operator, Stock Shapes

21 Born of tradition with an eye to the future

After three years of research and Wilfried Ensinger launches the production development, Ensinger produces its first A branch plant is opened in Cham. of quality semi-finished products in a garage thermal insulation profiles for window In 1986, Ensinger establishes its first near Böblingen. and facade construction. foreign subsidiary in the USA (photo).

1966 1977 1980

The milestones which have marked the development of the Ensinger Group tell the story of a family firm which has never been content to rest on its laurels. The continuous further development of products and production processes and the encouragement of employee potential have been essential aspects of our corporate mission since the very early days.

22 A branch plant is opened in Cham. The company makes available machined Ensinger establishes a new Another new building in Nufringen In 1986, Ensinger establishes its first materials for the growing Asian market injection moulding factory extends the company’s production foreign subsidiary in the USA (photo). from its base in Shanghai. in Rottenburg-Ergenzingen. and storage capacity.

2007 2009 1987 2008

Europe-wide expansion of semi-finished A new profile factory is constructed Klaus Ensinger leads the company product sales is launched with the in Cham with added production space in the second generation. Since 2002 formation of Ensinger Limited in Wales. and a high-bay warehouse. in association with Dr. Roland Reber.

23