Horst Scholz GmbH & Co. KG, a German-based plastics processing company, has significantly enhanced its tool correction processes by integrating ZEISS Reverse Engineering software into its workflow. This advancement has led to faster production times and improved precision in manufacturing high-quality injection-molded parts.
The Challenge: Streamlining Tool Corrections
Producing approximately 1.5 billion components annually, Scholz faced challenges in correcting injection-molded tools, especially for complex medical products like patch pumps. Previously, the design team relied on manual methods, transferring deviation data between scanned parts and CAD models into Excel spreadsheets—a process that was both time-consuming and prone to errors. This often resulted in five or more correction loops to achieve the desired tool precision.
Multiple medical products manufactured by the company Horst Scholz, including parts for the patch pump from the company Sensile Medical.
The Solution: Implementing ZEISS Reverse Engineering
By adopting ZEISS Reverse Engineering software, Scholz transformed its approach to tool correction. The software processes unstructured 3D point clouds from various sources, including contact measuring machines, CT scans, and laser scanners, to detect underlying geometries and reconstruct accurate CAD models. This capability allows for efficient comparison between scanned data and original designs, facilitating quicker identification and correction of deviations.
The scan data from the first manufactured test parts are compared with the CAD data. Errors can be quickly identified thanks to the false color display.
Frank Röder, an engineer in Scholz’s Design department, highlighted the impact: “Thanks to ZEISS Reverse Engineering software, we only needed two correction loops for the injection molded tools used to manufacture a patch pump – in spite of the challenging geometry and two different plastics being involved.”
The Outcome: Enhanced Efficiency and Quality
The integration of ZEISS Reverse Engineering has yielded significant benefits for Scholz:
-
Reduced Correction Loops: From five or more iterations down to just two, accelerating the production timeline.
-
Earlier Batch Production: The company commenced batch production for certain products more than five months ahead of schedule.
-
Improved Precision: Enhanced accuracy in tool corrections, leading to higher-quality end products.
Frank Röder, an engineer in the Design department at Scholz, describing the challenges of performing tool correction for injection-molded parts.
Karl-Herbert Ebert, Scholz’s Technical Manager, emphasized the value: “Offering maximum quality without losing sight of the costs for our customers.”
About Horst Scholz GmbH & Co. KG
Founded in 1974 and headquartered in Gundelsdorf, Germany, Horst Scholz GmbH & Co. KG specializes in injection molding technology. With a workforce of over 180 employees as of March 2017, the company has expanded into gear machines, micro technology, and medical technology. Its clientele includes global companies with stringent quality requirements, such as Bosch, Siemens, and Stihl.
