POLYRACK TECH-GROUP · Project-Based Manufacturing
Together with POLYRACK TECH-GROUP we develop the housing, covers and mechanical sub-assembly of your device from drawing to series production: thermoplastic injection moulding, die casting, sheet metal and surface finishing in one project.
One Partner Across Technologies
POLYRACK TECH-GROUP consists of POLYRACK Electronic-Aufbausysteme GmbH, the plastics company RAPP Kunststofftechnik GmbH and their subsidiaries abroad. The group focuses on developing and manufacturing customer-specific products and solutions: extensive consultancy in the concept stage, targeted development right from the start, production and assembly.
The group consults across technologies in sheet metal, plastics and die-cast components, since the best solution often comes from a mix of these technologies. Finishing the parts with technical or decorative surfaces completes the portfolio. In series production, quantities can range from several hundred to millions.
Manufacturing Technologies
Tool construction and injection moulding; one-, two- and three-component moulding. A three-component part is moulded in one shot in an automated process, with no pre-moulded parts or manual insertion.
Foamed thermoplastic moulding for large housing parts such as analyser covers, together with wet painting.
Aluminium, zinc and magnesium die casting; extruded profiles; machining and powder coating.
Robotic laser welding, CNC punching and milling; fully automatic laser-welded and galvanised sheet-metal assemblies.
Wet painting, powder coating, silk screen, pad printing, HD printing and electroplating.
Bonding and sealing with volumetric dosing; ESD-compliant assembly, cable assembly, function and final testing, packaging and logistics.
Focus: Medical Technology
Patients all over the world trust in the proper function of medical components and systems, so the medical industry rightly sets high demands on the quality and reliability of its suppliers. POLYRACK TECH-GROUP's customers build devices used in emergency ventilation, intensive care, patient monitoring, surgical procedures and inpatient treatment.
The group supplies parts and assemblies that form the mechanical basis of these devices or serve as design covers, and accompanies its customers from the early development stages. Early supplier involvement is not just a phrase.
The group's medical references include parts and assemblies for devices from Dräger, Philips, STRATEC and Stockert.
One- and two-component thermoplastic injection-moulded parts and sheet metal, mounted as a mechanical sub-assembly.
© Drägerwerk AG & Co. KGaA, Lübeck. All rights reserved.
Wet-painted foamed thermoplastic (TSG) covers and sheet-metal parts, mounted to a mechanical sub-assembly.
© STRATEC SE. All rights reserved.
Wet-painted foamed thermoplastic (TSG) parts, thermoplastic injection-moulded parts and laser-welded sheet-metal assemblies.
© Drägerwerk AG & Co. KGaA, Lübeck. All rights reserved.
One- and three-component thermoplastic injection-moulded parts; the handle is moulded in one shot in three components.
© Philips Medizinsysteme. All rights reserved.
An aluminium die-cast part, extruded profile and sheet-metal parts, machined and powder coated.
© Stockert GmbH. All rights reserved.
19" 5-slot microcomputer packaging system based on CompactPCI; a fully assembled functional unit.
Product Highlights
The Babyleo® TN500 IncuWarmer ensures constant, optimal thermoregulation in the open and closed care of premature babies and in the transition phase. Three synchronised heat sources protect the smallest patients from heat loss; easy access to the baby makes daily work easier.
Sheet-metal processing · fully automatic laser welding · galvanising · milling · injection moulding · thermoplastic foam moulding (TSG) · wet painting · powder coating · printing · assembly
IntelliVue X3 is a compact, portable patient monitor that can be used in two different ways, offering smartphone-style intuitive operation and a scalable set of clinical parameters.
The handle of the device is moulded in three components in one shot in an automated process; no pre-moulded parts or manual insertion are needed.
Three-component injection moulding
SmartAblate® is the market-leading solution for minimally invasive electrophysiological procedures, in which the source of a cardiac arrhythmia is treated safely and effectively with a high-frequency energy source.
Its mechanical structure combines several technologies: a sheet-metal case with an internal frame made of extruded profile; the operating elements sit in a hinged front made of powder-coated die-cast aluminium parts.
Aluminium die casting · extruded profile · sheet metal · machining · powder coating
© Stockert GmbH. All rights reserved.Project Process
Requirements, drawings and target cost. Design to cost: together we define the right product solution considering all technical requirements and the planned cost structure.
SolidWorks CAD, thermal simulation, filling simulation and distortion analysis, FEM calculation; first prototypes and integration samples that verify the function.
Design for manufacturing: an interdisciplinary project team, backed by experienced production technologists, focuses on stable and feasible processes from the first day of development to series production.
All production processes are qualified and verified at series start-up.
Long-term series production of single parts, components and complex assemblies; you decide which technologies and services you use.
Other Sectors
From high-precision connector housings for high-speed data transmission to monitor covers; a thermoplastic communications unit with threaded inserts and connector labelling. Applications in navigation, communication, reception and distribution technology, infotainment and measurement technology.
Enclosures for passenger information systems, remote I/O, onboard repeater equipment and the train network; long-life solutions built for shock and vibration.
Parts made with bonding and sealing technology: compact sealing materials of 16–60 Shore A, suited to enclosures with access doors that are opened for maintenance.
Manufacturing
More than 45 years of experience, more than 2,000 customers worldwide, more than 500 employees and more than 10 locations. The group's products are made in high quality with the economic benefits of series production.
With POLYRACK, Björn Tech is your single technical contact for projects in Türkiye: from drawing and 3D model to quotation, samples and series production.
| Injection moulding machines | Process-monitored moulding; clamping force 25 t, 50 t, 100 t, 200 t, 400 t, 650 t and 1300 t |
|---|---|
| Part weight | 0.5 – 6,000 g |
| Standard thermoplastics | PP, PE, PS, ASA, ABS, PMMA |
| Engineering and high-performance thermoplastics | PC, PA, POM, TPE, PBT; PPS |
| Part types | Thermoplastic parts, film insert moulding, TSG parts, multi-component parts |
| Prototypes | Stereolithography, selective laser sintering, vacuum casting, 3D printing |
| Tool shop and secondary processes | 5-axis and conventional milling, EDM, turning, grinding; metallisation of plastic parts, ultrasonic welding, insert technology and special machine building |
| Project support | Product design support, design for plastics, filling simulation and distortion analysis, project scheduling and a single contact |
Plastics, die casting, sheet metal and surface finishing in one project, with technical support from design to delivery.
The technology, or mix of technologies, is chosen together for the part's function, quantity and cost target.
After sampling and qualification, long-term series production and continuity of supply.
Send us your drawing or 3D model; together we will work out the technology, the tooling and the series production plan.
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