We love the perfection of moulded components.
We love the perfection of moulded components.

Moulded wood

The exciting variety of a natural design material

Becker Brakel’s production site is located next to the greatest beech wood growing area in the world. We process up to 20,000 cubic meters of beech wood every year. Beech is our most important and sustainable natural resource. Its never-ceasing flexibility, enormous tension, stiffness

and deformability make beech wood an outstanding and unique raw material. We have the knowhow and the corresponding pressing technology to realise extreme radiuses, unusually complex 3D deformations and minimal thickness.

Step by step –
from the trunk to the finished product

How we produce moulded wood components.

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Beech wood forest

Beech logs are harvested at the age of about 120 years. The forests in Germany have been cultivated sustainably for more than 300 years. We are committed to a responsible use of the resource wood and are therefore "Chain of Custody " and certified according to FSC (C135245) and PEFC (DC COC0255/05). Our customers can be sure that all the wood they buy comes from sustainable forestry.

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Veneer production

  • timber storage for up to 20,000 cubic meters of beech logs
  • large steaming capacity
  • own veneer production with two peeling lines
  • four veneer thicknesses are peeled off as standard
  • Electronic veneer sorting with eight quality levels
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Pressing tools

  • More than 100 flat, two- and three-side presses
  • Great output quantity through use of aluminium pressing tools
  • Induction heating of the pressing tools guarantees great dimensional stability
  • Use of adhesives with specific characteristics, depending on the product requirements
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CNC-Stations

  • 18 CNC machining centers
  • Own fixture construction with great flexibility
  • Great number of contour variations are possible
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Processing

At Becker we have a multitude of our own metal fitting solutions, which are used in combination with our mouldings. If requested by the customer, we protect the moulded wood surfaces by oiling, painting or putting on melamine layers. It is even possible to print on logos etc. Decorative laminates (HPL / CPL) of your choice are available.

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Material properties

Beech wood provides splinter-proof, impact-proof hardwood with high tensile, compression, bending and shear strength. The material is durable and robust and can be very well combined with face veneers and laminates. Countless variations of design can be made with a pressing tool for shells.

Tools Overview

Database with all relevant pressing tools

With an inventory of 1,300 pressing tools, we manufacture customized plywood and laminated wood components. You can find a detailed mould table below. Some of the tools shown are in customer possession, so we cannot press any parts made of them without permission.

However, if you are interested in one of these forms, we will arrange for you get a license. In addition to that, there has to be an agreement with the respective owner about the fee for using the tool.

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Decorative part

Tools, which are suitable for the manufactoring of decorative parts. In certain casas, it is also possible to press upholstery qualities in it.

Upholstered

Tools, which are exclusive suitable for the manufactoring of shaped parts in upholstery qualities.

Double Tool

Tools, which are manufactored for two or more shape wood blanks.

Aluminium

Tools, which are complitely consists of aluminium. They are construed for an high number of pieces per hour.

177
Seats
211
Backrests
210
Shells
47
Chair & armchair legs
21
Cantilever chairs
29
Four-legged chairs
73
Armrests
109
Construction elements
46
Square mouldings

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Becker know-how

Answers to your questions

Tools

Can I order a shaped part from the manual as a sample?

You can generally obtain samples for prototypes. To the extent that we have individual blanks in the warehouse, we can send them to you at short notice at your own expense. This manual furthermore informs you about our manufacturing programme and the many technical production possibilities. It also contains shaped parts made from tools that are owned by our customers and from which we do not press any parts without approval.

When should a tool made of aluminium be preferential to a wood tool?

An aluminium tool is preferential if the blank requires intensive shaping, particularly high precision is required or if high production numbers are planned.

How much does a pressing tool actually cost?

The price depends on the size, type and complexity of the shaped part. A pressing tool made of wood with aluminium heating plates costs from Euro 2,000. A pure aluminium tool begins at around Euro 6,000.

Why do you prefer electrically heated tools for pressing?

Electrically heated tools are particularly precise, because they generate even heat distribution, which can be very well controlled. The advantage: Comparably high form stability is achieved. 

Production

What are the minimum order quantities?

For efficient production, a minimum size of 250 units is necessary. However, in individual cases, a lower unit number per order can be agreed.

Which paint surfaces are possible?

For the protection of the wood surfaces, shaped parts are to be painted with DD or water-based pained, in a covering or transparent form. Through the use of staining, many different colour tones (e.g. maple, cherry, mahogany) are possible. In addition, the veneer can also be oiled and waxed.

Can ready-painted shaped parts also be sourced from you?

To the extent that the customer requires it, we can also offer shaped parts that are painted and assembled.

What is the difference between production tolerances and shape tolerances?

The production tolerance describes the dimensional deviation resulting from machine processing (milling, drilling, sanding) of the part. It is usually very low and lies within the range of tenths of millimetres. In contrast, shape tolerances result from moisture changes in the condition of the air in the room Through this, aperture angles change or flat shaped parts can warp. This must be taken into account with engineering and design.

Why must the trunks be steamed for 48 hours prior to peeling?

The wood must be sufficiently supple for the peeling process. We achieve this with steaming. For this, the trunks are fanned with hot water vapour in special steam pits for two days. Through this electronically controlled process, the even tinting of the wood is also created. Our process ensures an even wood colour throughout the year.

Can your glue fulfil the E1 standard?

Our glue system falls significantly below the threshold set in the E1 standard. Its compliance is regularly checked by an independent test institute.

Can fine veneers also be pressed?

Fine veneers (e.g. maple, cherry, oak, walnut or many other types of wood) can usually be pressed well. They are frequently used as sliced veneer for the decorative cover layer. The inner layers then consist of beech peeled veneer.

What are the largest dimensions for the shaped parts?

We can peel up to a veneer length of 2,220 mm gross. The width is limited by the size of the presses.

Which smallest radius is possible?

The thickness of the veneer determines the radius. With the veneer thickness of 2.3 mm, the smallest inner radius is 28 mm, with 1.5 mm, it is at 25 mm, with 1.1 mm, only at 18 mm and with a veneer thickness of 0.8 mm, it is even only 12 mm.

How long does it take to press a shaped part?

In order to achieve good adhesion, the part must remain in the press for a sufficient period of time, under pressure and heat. The following rule of thumb applies: Thickness of the part in millimetres, divided by 2, plus 4 minutes. A part with a thickness of 12 mm is therefore in the press for 12 : 2 + 4 = 10 minutes.

Development

Are you in a position of being able to produce prototypes?

Through our many years of experience in prototype construction and in the development of shaped wood for a wide variety of applications, we can build models at short notice. For this, we maintain a specific development workshop with ten qualified carpenters and master model builders. In the workshop, samples, prototypes and equipment are produced. In cooperation with you, through the use of our unique seat simulator, we are in a position of creating chair models that can be "sat on" within a few hours.

Why should the supplier already be integrated into the development process at an early stage?

Experience has shown that particularly at the beginning of development, the decision regarding execution and design are material to determining the costs of the end product. With our longstanding know-how, we are able to assist in setting the course for an optimum price/performance ratio.

Which drawing formats can be processed with you in the engineering design department?

Our design engineer are specialised in Autocad 2000, Rhinoceros, Creo 2.0 and Mastercam. Furthermore, all conventional file formats can be read and processed by us.

Can shaped wood be combined with other materials?

Moulded wood can be directly pressed with plastic films, decorative papers, foundation films and similar materials.

Material

Which fields of application are there for shaped wood?

Inherent in the multifaceted material and design advantages is the fact that the emphasis of application lies in furniture construction. However, in addition, shaped wood is also used in the field of toys, vehicles, interior fittings, with musical instruments, for accessories and in technology (cable drums, transport troughs, etc.).

Why is peeled veneer used?

The manufacturing of peeled veneer is significantly more low-cost and therefore more cost-effective than cut veneer, as with veneer always need to be joined together into a sufficiently large veneer sheet and glued, due to its relatively narrow strips.

Why do you choose beech wood?

On the one hand, due to the durability of the beech wood, due to its flexibility, its processing and shaping possibilities. And on the other hand, because all of this is available at a very good price/performance ratio.

Is it difficult to produce flame-retardend moulded plywood?

With our Becker Incendur® process, we are able to offer flame-retardend moulded plywood. It meets international standards. It is used for train seats and airport seating.

How thick is the veneer that you manufacture?

We produce three standard thicknesses: 1.1 mm, 1.5 mm and 2.3 mm. In addition, there is a special thickness of 0.8 mm. With it, we can also produce parts that require very narrow radii.

What is the difference between laminated plywood and cross-plywood?

With the structure of laminated plywood, the veneers are all laid in the same fibre direction and glued. This achieves a very high level of tensile strength - exactly right for bars, armrests and cantilever side parts. With the structure of cross-plywood, the veneers are laid crosswise ("locked"). This way, a high degree of form stability is achieved with flat parts, such as seats, backrests and chair shells.

How heavy is beech per cbm?

The raw beech wood weighs an average of between 680 kg/cbm (with 12% moisture content).

How long will the trunk wood reserves last in the beech forests?

The round wood that we use comes exclusively from so-called sustainable, German forestry. Sustainability means that only the amount of wood is cut that grows again. Through the strict law of sustainability, the supply is also ensured for the coming generations. The German forests are certified according to the ecological quality seals, "PEFC" and "FSC". Both organisations are dedicated to sustainable management and the retaining of forests with their multifaceted functions. (FSC stands for Forest Stewardship Council www.fsc.org, PEFC for Pan European Forest Certification www.pefc.org)

Where do you obtain your beech trunk wood from?

Our purchasing regions lie directly on our doorstep. They are primarily the federal states of North Rhine-Westphalia, Lower Saxony and Hesse.