1K, 2K, insert or outsert: what is the difference?

In 1K injection moulding, the part is made from one injection moulded plastic component. In 2K injection moulding, two components are combined one after the other in one mould, for example a dimensionally stable polycarbonate part and an elastic TPE seal. In insert moulding, an insert, often made of metal, is positioned in the mould and overmoulded. In the outsert process, plastic functional elements are moulded onto a metal carrier. Which process fits depends on function, material combination, installation space and the desired degree of integration.

Which materials do you process?

We process a wide range of thermoplastics. These include PE, ABS, POM, PBT, polycarbonate, PA 6, PA 66 and the high-performance thermoplastic PEEK. Thermoplastic elastomers are used for elastic components and moulded-on seals. Depending on the requirements, we process unreinforced, glass-fibre or glass-bead filled, as well as UV-stabilised and flame-retardant material grades. Die-cast aluminium parts can also be overmoulded in the hybrid process.

Can you integrate metal directly?

Yes. Threaded bushes made of nickel-plated brass, contacts or busbars from our own stamping and bending technology are positioned directly in the injection mould and overmoulded. The metal parts are thus firmly integrated into the plastic part in exact position. Separate joining and assembly steps for these components are eliminated.

How is your series production set up?

We produce 1K and 2K parts on 21 injection moulding machines from Arburg, including fully electric machines. Our own toolmaking, part-specific automation and quality assurance and metrology accompany the process from sampling to ongoing series production.

What do you produce in stamping and bending technology?

We produce electrical and mechanical precision stamped and bent parts from strip and, where required, from wire. These include contacts, clamping bodies, plug and socket contacts, solder pins, earthing contacts, clamping springs, clips, brackets and profile parts. Many series parts are produced finished off the tool on Bihler stamping and bending machines and eccentric presses.

Which strip and wire materials do you process?

We process a wide range of materials. These include cold-rolled steel strip such as C45E, spring steel such as C67S, stainless chrome-nickel strip as well as brass, copper and bronze. Pre-coated strip and selected wire materials are also possible. Two different metal strips can be combined into a dual-strip part in an automated process. Depending on the requirements, hardening or electroplated surface finishing follows, for example tinning for contact properties and solderability, nickel plating for corrosion and wear protection, or zinc plating to protect steel parts.

Can threads be formed directly?

Yes. In clamping bodies, contact plates and other stamped and bent parts, internal threads can be formed directly in the running production process. Where required, the entire threaded part is then hardened. This increases load capacity and creates additional torque reserve for demanding installation conditions.

Do you produce semi- or fully automatically?

Both. We produce series fully automatically on our stamping and bending machines. For feasibility studies, pre-series and small quantities, we can initially work semi-automatically with application-specific stamping, bending and assembly fixtures. This allows the function to be tested early without having to build a complete series tool straight away. The later precision tools are made in our own toolmaking shop.

Why do you have your own toolmaking shop?

Our own toolmaking connects development, production and maintenance directly. This allows us to match tools to the series process, implement changes quickly and secure their availability over the entire life cycle. The result is short coordination routes and stable production processes.

Which processes do you use in toolmaking?

We design the tools in 3D CAD and manufacture them by CNC wire EDM, die-sinking EDM, milling, turning and grinding. For EDM, we work with Fanuc and Mitsubishi controls. Assembly and tuning of the tools are also carried out in-house.

What does toolmaking do besides building new tools?

Our toolmaking shop looks after the tools throughout their entire life cycle. Before and after each production run, they are inspected, cleaned and checked against the documented last production status. Moving components are lubricated and wear parts checked. On top of this come preventive maintenance, repairs and necessary changes. This increases tool availability and supports consistent series quality.

What does system supplier mean in practice?

As a system supplier, we take responsibility for the complete, ready-to-install assembly. We combine engineering, toolmaking, injection moulding, stamping and bending technology and assembly with coordinated bought-in and partner services. You receive a coordinated assembly, one delivery and one central contact.

Do you also organise bought-in parts?

Yes. We select and source standard parts for the application. Where required, we help design drawing parts, specify them and coordinate their production, for example for die-cast or machined parts. Full provision of material by the customer is not required.

Do you assemble manually or automatically?

Both. We assemble manually for small and pre-series and automatically for larger quantities. The agreed scope of supply can also include marking with Data Matrix or QR codes and packaging in returnable containers or thermoformed trays with exact position and orientation.

Do you hold stock for us?

Yes, to the agreed extent. With framework agreements, long-term raw material planning and build-to-stock inventories of semi-finished products or finished assemblies, we increase delivery capability and help to absorb short-term peaks in demand. Orders can be transferred automatically into our system via EDI.

Injection Moulding, Stamping, Toolmaking

Sepro 6X Visual handling robot with gripper at an injection moulding cell at Friedrich Joerg

Capabilities

From the metal-plastic bond to the ready-to-install assembly: eight capabilities, combined at one site, since 1920.

Send a drawing View processes ↓

Core Material composites · 01 Moulding · 02 Stamping · 03 Toolmaking · 04 Engineering · 05 Assembly

Friedrich Joerg GmbH

DesignationCapabilities

Scope8 areas

Our capabilities at a glance

Eight capabilities through to the finished assembly.

Development, material composites, toolmaking, production, finishing and assembly interlock at a single site. Quality accompanies every one of these steps, from the first drawing to the inspected assembly.

Sparks and coolant at a copper electrode in an EDM machine in the Friedrich Joerg toolmaking shop — Play film

01Engineering
02Composites
03Toolmaking
04Moulding
05Stamping
06Finishing
07Assembly
08Quality

Friedrich Joerg design engineer checking a part with a calliper and evaluating the results digitally

01Capability

Engineering for series production

Series readiness begins before the first tool is built. In simultaneous engineering, we align part geometry, material, tolerance chains, manufacturability, tool concept and total cost at an early stage. Toolmaking, production and quality work together from the outset, so that technical and commercial risks are identified before they become expensive in the tool or in series production.

What we validate before tool release

DFM review (design for manufacturing) of the part geometry for injection moulding, stamping and bending, and assembly
Material selection by function, load, temperature, media and certification requirements
Tolerance chains and interfaces between metal, plastic and assembly components
Filling, cooling and warpage analyses for injection moulded parts, with Moldflow where required
Tool, process and automation concept geared to economical series production
Quality-critical characteristics, testability, and production and relevant life-cycle costs

Result

A documented DFM report with clear recommendations, technical risks and a sound basis for tool and process release. This reduces late changes and makes costs, deadlines and series start-up easier to plan.

3D part in engineering

360° from design data

A2473 · DFM review

Before tool release

For the holder arm A2473, we added a functional plastic bayonet lock to the original part data. Locking geometry and local stiffness were matched so that the required snap-in and release forces were achieved: loaded areas were stiffened, others deliberately designed to be flexible. The documented optimisations went directly into the 3D data before toolmaking.

Article: A2473 · Holder arm
Phase: DFM and process design
Focus: Manufacturability and series risks

02 · Material composites & functional integration

When metal and plastic
become one part

Our strength lies in how the processes work together. We combine different materials into a functional unit and integrate additional functions directly into the part, from light guides to media seals.

Metal and plastic react differently to temperature changes, vibration and mechanical load. A material composite that works reliably over time is therefore not created by overmoulding alone. What matters is the interplay of material pairing, part geometry, surface, tool design and stable process control.

Depending on the application, undercuts and other geometric anchoring features secure the form fit. Where the material pairing requires it, suitable surface treatments or adhesion promoters are also used. Tool temperature control and matched process parameters help to limit internal stresses and to produce the bond reproducibly in series.

Series part and its CAD model, where the metal-plastic interface is designed

The material composite begins in the design: material pairing, anchoring geometry, sealing areas and process control are defined before the first tool is built.

Insert moulding

Anchoring metal inserts in the plastic by form fit

In insert moulding, a prefabricated metal part is positioned in the mould and then overmoulded with plastic. Undercuts, knurling or other anchoring geometries secure the bond against twisting and pull-out.

This is how nickel-plated brass threaded bushes are anchored by form fit in the glass-fibre-reinforced PBT of a terminal block for frequency inverters from 24 to 1,000 V. The bond can transmit the required torque, while a later joining and assembly step is no longer needed.

Outsert technology

Plastic functions on a metal carrier

In outsert technology, plastic or elastomer functions are moulded onto a comparatively large metal carrier in a targeted way.

On a base plate for electric motors, a sealing geometry made of thermoplastic elastomer is moulded directly onto the die-cast aluminium carrier. The seal is therefore clearly positioned during manufacture. Separate inserting and fixing is no longer needed.

2K hard-soft

Carrier and seal in one process cycle

In 2K injection moulding, the hard and soft components are processed one after the other in one mould. First the load-bearing hard component is formed, then the sealing geometry made of a thermoplastic elastomer is moulded directly onto it.

On an electrical cover, a polycarbonate carrier and the directly moulded-on TPE seal form a single part. This eliminates the separate insertion of a seal, and its position is reproducibly defined. The required sealing performance is designed and tested in the fully assembled unit.

3D part in detail

360° from design data

A2305 · Insert moulding

Aluminium frame and TPE seal in one part

In insert moulding, the aluminium frame is positioned precisely in the mould. The thermoplastic elastomer is then moulded directly onto the frame. TPE can be processed like a thermoplastic and behaves elastically in later use.

The two materials perform different tasks: the aluminium frame dissipates heat from the electronics area, ensures dimensional stability and supports the sealing geometry from the inside. The moulded-on TPE takes on the elastic sealing function. The result is a part with integrated functions that requires no separately fitted seal.

Article: A2305 · Aluminium frame with integrated TPE seal
Process: Insert moulding with TPE
Materials: Aluminium and thermoplastic elastomer
Functions: Heat dissipation, dimensional stability and sealing

One part. Three functions.

Dissipate heat. Support the seal. Save assembly.

Within the assembly, the aluminium frame performs a thermal and a mechanical function at the same time. It dissipates heat from the electronics area and stabilises the geometry of the part. At the same time, it supports the moulded-on TPE seal from the inside, so that its position and contour remain permanently defined.

7–8 K

lower part temperature thanks to the aluminium frame

CAPTIVE

TPE seal permanently positioned on the frame

ONE OPERATION FEWER

no separate seal assembly required

The elastic TPE forms the actual sealing geometry. Because it is moulded directly onto the frame, the seal is captively connected to the part and protected against shifting during handling, assembly and external stress. The bond is designed for the intended life cycle of the product.

At the same time, the separate provision, positioning and assembly of an additional seal is eliminated. Two materials thus become a ready-to-assemble part that combines heat dissipation, dimensional stability and sealing.

Toolmaking hall with machining centres at Friedrich Joerg

03Capability

Toolmaking & automation

Series quality begins with the tool and comes from the stable interplay of tool, machine, handling and inspection. We develop, design and build injection moulds and stamping and bending dies, as well as assembly, inspection and automation solutions, in-house.

Toolmaking is where it is decided whether a solution runs stably in series. We design injection moulds and stamping and bending dies in 3D CAD and manufacture the required components by CNC wire EDM, die-sinking EDM, milling, turning and grinding. Design, manufacture, tool assembly and maintenance are aligned with each other from the start. When tools need to be adapted, serviced or repaired, the routes stay short in-house. This reduces response times and production interruptions.

Series production takes more than the tool. We source base machines, drives, linear axes and robots from established manufacturers. We develop and implement the application-specific system concept, assembly stations, grippers, fixtures and the mechanical and electrical integration ourselves. In a linear concept, one unit moves to several assembly stations. Alternatively, the system can be built as a rotary indexing system. Control systems and programming are also created in-house.

What we can do

04 Service modules

In-house tool design

Design in 3D CAD, closely coordinated with development and production. Laid out from the start for the series process, assembly and maintenance.

EDM & machining

CNC wire EDM and die-sinking EDM with Fanuc and Mitsubishi controls. Milling, turning and grinding for complex contours and precise mould inserts.

Application-specific automation

Bought-in base machines, drives and robots. Our own assembly stations, gripper systems, module heads, fixtures, system integration and programming.

Changes & maintenance in-house

Adaptation, servicing, repair and trials in our own toolmaking shop. Short response times without external transport and coordination.

Tools and production

Nozzle-side mould half with removed slides during cleaning and maintenance — Tool maintenanceNozzle-side mould half with slides removed for thorough cleaning and maintenance.

Ejector side of a hot runner mould with slides and angle pins — Hot runner mould with slidesEjector side with angle pins for the slide movement during opening and closing.

Fine ejector pins being inserted by hand into the ejector plate — Ejector plate with fine ejectorsFine ejector pins are fitted precisely into the ejector plate.

3D tool in detail

360° from design data

A2272 · Injection mould SVB14

From 3D CAD to series tool

Shown is an open injection mould with a view of the nozzle side and the ejector side. Mould inserts, gating, guidance and temperature control are matched to the part geometry and series process as early as the 3D CAD design. Design, manufacture, assembly and trials take place in our own toolmaking shop.

Article: A2272
Tool: SVB14
View: Nozzle and ejector side
Basis: 3D CAD design

CNC machining of a copper electrode in the Friedrich Joerg toolmaking shop

From the toolmaking shop

We mill the copper electrodes for our injection moulds ourselves and use them for die-sinking EDM of the mould inserts. Copper is particularly suitable for fine contours and high surface quality. This produces precise cavities for reproducible series parts.

Frequently asked

Operator at a fully electric Arburg injection moulding machine at Friedrich Joerg

04Capability

Plastic injection moulding

On 21 injection moulding machines, including fully electric machines, we produce single and multi-component parts from engineering and high-performance thermoplastics. With 1K, 2K, insert and outsert processes, we integrate metal parts, seals and other functions directly in the mould. Where required, we then also take on assembly into the complete electromechanical assembly.

For our customers, both the precise individual part and the fully functioning assembly can be decisive. That is why we do not look at even a simple injection moulded part only by its drawing: we take function, mechanical loads, installation space, interfaces, tolerances and ambient conditions into account, and consider the later assembly from the start.

Where the task makes it sensible, we integrate further functions directly into the injection moulding process: for example contacts and threaded bushes, including from our own stamping and bending technology, hard-soft bonds or seals. This lets us deliver exactly the degree of integration the project needs, from the demanding individual part to the ready-to-install assembly.

We select materials together with our customers based on the actual requirement profile. Decisive factors include mechanical loads, impact strength, dimensional stability, temperature, vibration, humidity, UV radiation, chemicals and cleaning agents, as well as fire behaviour and certification requirements.

We process standard thermoplastics, engineering thermoplastics, high-performance thermoplastics and thermoplastic elastomers. We keep many common material grades in stock; special compounds are selected and sourced for the application.

Injection moulding machines from Arburg and Demag

1K · 2K

Single and multi-component injection moulding

PE TO PEEK

Thermoplastics and TPE

What we can do

04 Service modules