mm
5-axis machining up to 4400 x 2400 mm part size.
mm
Cooling holes up to 2500 mm in one go.
Tons
over 50 metric tons in tool weight
Sampling
Every year, we perform more than 500 sampling tests.
INJECTION MOLDING TOOLS AND Complex CNC Machining
Precision from Our Own MANUFACTURING
MÜLLER WALLAU develops, designs, and manufactures highly complex injection molds as well as customized mold solutions for a wide variety of manufacturing processes and sophisticated components across a broad range of industries.
Our range of services covers virtually all tool sizes—from compact precision tools to large-format tools weighing over 50 metric tons.
To this end, we have two physically separate, specialized toolmaking divisions: one for small and medium-sized injection molds and one for large and heavy-duty mold designs. This clear specialization enables optimally coordinated manufacturing processes, efficient workflows, and a high degree of flexibility in meeting a wide variety of project requirements.
With in-house design capabilities, a high degree of vertical integration, and a state-of-the-art injection molding facility, we bring together all key areas of expertise under one roof. From tooling development through manufacturing and assembly to pre-production prototyping, we support our customers with technical expertise, experience, and a commitment to high standards of quality and cost-effectiveness.
Specialized toolmaking divisions for small and large tools
> 100 tools per year
> 500 sample inspections per year
Tools weighing between 200 kg and over 50 metric tons
18 CAD design workstations
more than 160 skilled workers in toolmaking and machining
3 Injection molding machines
Design of Complex Tools
Design & Development
Every plastic component poses unique challenges for mold design. Our 18 experienced design engineers develop innovative and cost-effective mold concepts for challenging geometries and complex injection molding processes. We combine technical expertise with state-of-the-art CAD technology and many years of experience—from the initial idea to a production-ready design.
Tool technology
- 1K tools
- 2C tools (turntable, pick n place, cube)
- Stack molds (1-fold, 1+1-fold, 2+2-fold)
- Back injection molds
- Injection stamping tools
- Precision opening tools
- Embossing tools
Toolmaking specialist
Our range of services extends from high-precision molds for the smallest chrome-plated plastic components—weighing as little as 2 grams—to complex multi-cavity molds for the simultaneous production of four door panels.
Our particular expertise lies in sophisticated mold technologies: About 15% of our molds are two-component injection molds, and another 20% are back-injection molds for textiles, decorative films, and other surface materials. In addition, we develop and manufacture custom embossing and pressing tools as well as innovative custom solutions.
This range of capabilities enables us to meet a wide variety of tooling requirements—from delicate precision components to large-scale and technologically complex applications. Our focus is on well-thought-out tooling concepts, cost-effective manufacturing processes, and reliable mass production.
2K and Multi-Component Technology
#Turntable #Displacement technology #Pick n Place #Tandem #Slide gate
Back-coating of textiles, leather, and decorative films
(PUR) Polyurethane Overflow
#In-Mold Coating, #ColorForm
stack molds
#1+1 #2+2 #1+1+1+1
Foam injection molding
#Precision opening #Foaming
Insert molding
#Hybrid components #Metal and plastic
Embossing tools
#Prägen
Press Tools / Composite Tools
Injection Molding Technology & Process Development
SAMPLING & DEVELOPMENT
In our in-house injection molding pilot plant, which is equipped with three injection molding machines, we test and optimize complex injection molds under conditions that closely resemble those of mass production. Our range of technologies extends from traditional 1K and 2K injection molding to multi-component processes and sophisticated back-injection molding. By integrating state-of-the-art robotic automation and systematically optimizing injection molding processes, we ensure the functionality of the molds and lay the foundation for cost-effective and reliable mass production.
Technologies
- 3 injection molding machines (850t, 2000t, 3000t) incl. Robot Automation
- SGI
- Precision opening
- Foaming
- Emboss
From Design to Component in No Time
Prototype tools and small-batch production
We develop and manufacture prototype molds made of aluminum or based on proven master mold systems. Our in-house design and mold manufacturing capabilities enable exceptionally short lead times and rapid adjustments. At our plastics technology center, we produce near-production components from the specified plastic material—for functional testing, material and process optimization, and small-batch production.
Toolmaking
We manufacture tools ranging from 200 kg to over 50 metric tons.
