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.
An aluminium tool is preferential if the blank requires intensive shaping, particularly high precision is required or if high production numbers are planned.
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.
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.
For efficient production, a minimum size of 250 units is necessary. However, in individual cases, a lower unit number per order can be agreed.
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.
To the extent that the customer requires it, we can also offer shaped parts that are painted and assembled.
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.
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.
Our glue system falls significantly below the threshold set in the E1 standard. Its compliance is regularly checked by an independent test institute.
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.
We can peel up to a veneer length of 2,220 mm gross. The width is limited by the size of the presses.
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.
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.
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.
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.
Our design engineer are specialised in Autocad, Rhinoceros, Creo and Mastercam. Furthermore, all conventional file formats can be read and processed by us.
Moulded wood can be directly pressed with plastic films, decorative papers, foundation films and similar materials.
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.).
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.
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.
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.
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.
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.
The raw beech wood weighs an average of between 680 kg/cbm (with 12% moisture content).
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)
Our purchasing regions lie directly on our doorstep. They are primarily the federal states of North Rhine-Westphalia, Lower Saxony and Hesse.