ADVANCED DESIGN CENTERtexture and surface design | prototyping | feasability | R&D | technical consulting

T H E A R T O F P E R F E C T I O N

To be able to sell a product successfully on the market, is be-side high quality components a modern product and surface design essential. According to our slogan „the art of perfec-tion“ we support you with our modern technology of laser texturing not only in reference to high quality, but especially also in the area of matt surfaces in all plastics.

For this purpose, we have already fully ceased the traditional chemical etching in 2013 and realize all grainings exclusive-ly by means of absolutely reproducible and fully digital laser technology; and this worldwide with uniform quality stan-dards.

In our „Advanced Design Center“ we develop constantly new textures suitable for your product and advise you in all matters. We work worldwide and cross-industry, e.g. for automotive, motorcycle, airplane, light, electrical appli-ances, cosmetics, household, medicine, and much more.

Rely on our dynamic innovative strength and our decades of know-how in state-of-the-art technologies and design trends, in order to jointly create and realize perfect surfa-ces and products.

TEXTURE DEVELOPMENT

If you cannot find a suitable texture from our collection or have your own creative ideas, we are happy to develop a completely new texture exclusively for you.Some of the possible steps include:

• Development of a new texture or texture family• Visualization via sketches or 3D renderings• Production of prototype foils for short-term first inspec-

tion as physical sample• Laser texturing of our changeable steel insert incl. pro-

duction of sample plaques in your desired plastic material• Execution of material tests and parameter studies on our

own injection moulding machine• Texture optimization for scratch and write sensitivity• Optimization of the texture for optical or haptic features

• Development of a material- and part-comprehensive quality standardization concept (e.g. no visible diffe-rence between PP and PC-ABS by our special texture)

• Development of a Low-Gloss or Ultra-Low-Gloss concept with your graining (matt gloss levels in all plastics or anti-reflective properties)

TEXTURE REPLICATION

In order to achieve grains realized with the conventional et-ching process, process-safe and fully digital with laser, existing chemical etched grains must be replicated. From then on they are identical to the master sample and can be contributed in all injection molds independent from each other; and this worldwide with identical quality and short processing times.

• Identical graining according to customer‘s design (sample plaque or part, textile, foil, fabric, etc.)

• Digitalization of grain patterns incl. measurement• Development of necessary grayscale bitmap for reali-

zation using the latest laser technology• Optimization of the graining for maximum efficiency

during the laser process• Optimization of the grain appearance or characteris-

tics (blotchiness, defects, scratch and write sensitivity, etc.)

• Production of plastic sample plaques on our own injection moulding machine

• Production of master sample plaques and measure-ment reports

INNOVATION | CONCEPT DEVELOPMENT | TECHNICAL CONSULTING | MANUFACTURING CONCEPTS

In order to realize perfect plastic parts, numerous adjustments and decisions are necessary before the graining process will be done. For this we support and advise you in the following topics:

• Consulting in the field of materials, manufacturing concepts and finishing processes such as vaporizing, coating, painting, chrome-plating, illumination, emboss-ing of wood decors, foil back injection moulding, and much more.

• Development of technical framework conditions for im-plementation of a desired surface design (manufacturing process, tempering, tool design, and much more)

• Feasibility studies on the basis of product or tool data (analysis of the draft angles, accessibility of the laser beam, etc.)

• Creation of possibly necessary offset concepts for the mould construction

• Simulation, design, development and visualization of special light outcoupling or diffusion structures for light guides

• Analysis of product or tool data for potential risk factors regarding surface and appearance quality incl. develop-ment of possible solutions

• Development of cost saving potentials thanks to special developed surface concepts such as paint elimination, anti-reflective textures, elimination of wrapping foils, and much more

• Cost reduction workshops based on surface and texture design

• Selection of potential partners for mould and tool construction, injection moulding purchase, finishing, etc.

• Implementation of a holistic project management• Development of application-related surface concepts

with our special technology of laser texturing: - Reduction of the scratch and write sensitivity - Replacement of coating processes thanks to special textures - Realization of anti-reflective surfaces without paint for applications like head-up displays, strey light bezels, defroster bezels, loudspeaker grilles, and much more. - Realization of matt gloss levels even in amorphous plastics without painting (e.g. PC, PC-ABS, etc.)• False light reduction in head lights and tail lights

thanks to special anti-reflective textures• Light outcoupling structures for light guides for an

extremely homogeneous light appearance• Replacement of foil wrapping processes thanks to

highly detailed textures or soft-touch PUR• Development of anti-slip structures• Development and realization of holograms for

authenticity certification, and much more

DESIGN CONSULTING | DESIGN DEVELOPMENT

We advise you comprehensively on the basis of your product data or sketches and develop together with you inspiring surface concepts for a single component or also for a whole product family; everything completely individual according to your wishes. You can rely on our huge texture selection or we develop a completely new texture individually for you. To the further possible consulting scopes belong:

• Target group and product family analysis• Elaboration and development of holistic material,

surface, color and texture concepts• Development of individual textures for a product, a

product family or for your whole company• Definition of a-surface and secondary areas• Creation of sketches, drawings or renderings for

initial visualization• Realization of workshops for design finding, together

with your designers

3D RENDERINGS FOR HIGH-END VISUALIZATION

We create high-resolution 3D renderings for you to show first design ideas and concepts, for presentation and coordi-nation of detailed texture alignments and boundaries or for customer and directorate presentations. Due to the fully digi-tal processes in connection with modern technology of laser texturing we can guarantee that all digitally displayed details

can be laser textured into your serial injection mould with- out any deviations. I.e. you receive via our 3D renderings high-resolution images well in advance, which you can also use as a quality standard for the later serial product.

MAPPING

Organic and geometric textures warp naturally on convex or concave free form surfaces. Thanks to our mapping process, we can influence and define this natural warpage freely and together with you, adapted to your product, achieve the hig-hest possible level of visual aesthetics. We are also specialized in the development of cross-component mapping. I.e. that textures, that skip from one part to another, have a homoge-neous continuation without break.

Topics such as clearance, split lines, etc. are taken into account, so that your complete product, occurs to the end customer as if it’s from a single source. Provided that necessary, we also optimize and repair your 3D data or the mesh. The mapping is always digitally coordinated with our customers in advance of the laser process. In this way we generate a maximum of process reliability and quality.

LASER TEXTURING – The better alternative in comparison to conventional etching

Since 2012 we are using in the field of graining of forms, tools and individual parts exclusively the modern technology of laser texturing and are considered with more than 15 laser systems as market leader in Europe. As the only company we realize beside inspiring 3D textures also all conventional grains (eroded or etched) exclusively by means of laser technology, in order to be able to offer you a maximum process reliability, highest quality standards, absolute ensure reproducibility and fast processing times. You will not receive our services only in our headquarters in Germany, but also in China, Portugal, USA and Canada.

We take over the project management, R&D, the design, mapping and programming centrally from Germany. At all foreign locations only the laser texturing process by means of Reichles standardized laser systems takes place.

More than 40 laser texturing machines are available world-wide to carry out even complete vehicle projects globally at short notice.

PROTOTYPES WITH DETAILED GRAINING

A digital presentation of your product including the texture can significantly reduce the design development times, but there is often the desire to create physical samples. We create prototype components for you on request including the al-most real texture of a later serial plastic part.A special prototype foil was developed for this purpose by us, which shows an unprecedented level of detail. With this, high gloss, fine structures, leather grain, geometrical textures, texture fade-outs, and much more can be shown.

• Creation of carrier and a-surface components from 3D-printed plastics, CFK, GFK, clay, ureol, and much more

• Production of special prototype foils for representa-tion of the serial texture

• Carrying out of the wrapping process for applicating the serieal texture on to the part

• Carrying out component finishing such as grinding, polishing, painting, wrapping, assembling, and much more

• Delivery of complete vehicle interiors or exteriors for prototypes and showcars incl. detailed serial texture

PROCESS SUPPORT | TECHNICAL CONSULTING | QUALITY OPTIMIZATION

Our area of responsibility in the narrower sense is over after the graining of your moulds and tools using laser technology, but we support you with our extensive know-how also after-wards for your series and release processes:

• Supervision and support during injection moulding to achieve the best possible surface quality

• Supervision and support during the release and approval process until to your end customer

• Independent fault analysis of plastic parts (sink marks, holograms, ghosting, high gloss, glossy spots, demoul-ding problems, matt areas around the gate, and much more)

• Development of possible optimization measures in the injection process or on your moulds

• Measurement, logging and comparison of gloss levels, grain depths, and much more

• Preparation of independent expert opinions on component quality, grain characteristics and cause of defect

• Neutral advice as an expert in discussions with your end customer

• Subsequent cost reduction through concept develop-ment like e.g. elimination of coating or wrapping processes with the help of special laser textures

T H E A R T O F P E R F E C T I O N

Reichle Technologiezentrum GmbH | Alte Weberei 6-8 | 73266 Bissingen/Teck - GERMANY | www.reichle.de | info@reichle.de

USADetroit

GermanyStuttgart

PortugalOliveira de Azeméis

ChinaSuzhou

ChinaDongguan

KanadaOldcastle

USAPittsburgh