Deckerform at Fakuma: when the pace of development becomes a competitive advantage

Fakuma demonstrated the pace of development in the plastics industry and the growing importance of short development cycles, practical processes and cooperation between project partners. For Deckerform Technologies, the trade fair provided a platform for technical discussions and for presenting how the company combines technical innovation with a practical approach to implementation.

Together with its partners, Deckerform presented specific methods for accelerating toolmaking and product development in Friedrichshafen. Its stand in Hall A5 focused on three areas: the newly established plastics workshop at the company's headquarters in Aichach, cooperation with Possehl Consulting and a live demonstration with Leonhard Kurz Stiftung & Co. KG. The exhibits and technical discussions showed how closer coordination between partners can improve the efficiency of development and production processes.

Testing ideas directly in the material

The plastics workshop has been established as a practical laboratory for product development. Its underlying principle is that examining technical issues directly in the material at an early stage enables informed decisions to be made more quickly.

The team works with a range of materials and manufacturing processes, produces prototypes and test set-ups, and assesses technical properties under practical conditions. Sawing, screwing, milling, bending, foaming and 3D printing are used to generate findings that can be incorporated into the development process as early as possible.

At Fakuma, Deckerform emphasised that technical parameters should not be considered only on a screen or in simulations. They should also be verified in practice at an early stage. The objective is to work with customers to remove development barriers and establish a practical technical basis from the beginning of a project.

Live demonstration of surface finishing

A joint live demonstration with Leonhard Kurz Stiftung & Co. KG showed how injection moulding and surface finishing can be combined. Using the modular Catwalk Integral cat staircase, the partners demonstrated a newly developed five-axis hot-stamping machine that precisely finished the staircase steps at the stand.

The process applied was contour-following roll-on hot stamping. The demonstration presented an integrated approach in which toolmaking, injection moulding and finishing form one coordinated production system rather than separate process stages.

Process organisation based on the China Speed concept

Deckerform also shared a stand with Possehl Consulting. The presentation examined how implementation methods used by successful industrial companies can be transferred to established small and medium-sized enterprise structures.

Under the term China Speed, Possehl Consulting has analysed why companies in China can sometimes bring products to market considerably faster. According to the consultancy, the difference results less from a faster pace of work than from how decisions and processes are organised. Relevant factors include small decision-making groups, clearly assigned responsibilities, interdisciplinary teams, early involvement of all partners and development stages carried out in parallel rather than sequentially.

Deckerform considers this approach consistent with its role as an agile development partner. While the plastics workshop supports rapid technical decisions at the workpiece, Possehl Consulting addresses the organisational framework. This combination attracted interest from visitors seeking to accelerate projects within their own organisations.

Project examples with short implementation times

Deckerform presented two client projects to illustrate how the approach can be applied in practice.

Thin-walled label using IMD Slimline transfer technology: Six weeks passed between the joint decision to proceed and completion of the product for dispatch. The concept and design were finalised within one week. Design and surface finishing, including laser engraving, required a further four days, while the final design film was produced within three weeks.

Development of a seat cushion spring: This project combined product development, analysis and toolmaking. Eight weeks passed from initial prototyping to production of the first injection-moulded spring. Product development and analysis required two weeks, followed by six weeks of toolmaking before the first fault-free sample part was delivered.

Integrated services from product to machine

Deckerform's service range covers the initial concept, product development, mould making and injection moulding. Integrating these process stages allows development decisions to be coordinated across interfaces and implemented directly.

The portfolio also includes the exclusive distribution of fully electric Toyo injection moulding machines in German-speaking countries. The machines are developed and manufactured in Japan, and are intended to provide high energy efficiency and stable processes in series production.

Technical dialogue supports faster development

Deckerform assessed its participation in Fakuma positively, particularly because of the detailed technical discussions concerning practical challenges and potential joint projects. The company identified direct exchange between project partners as an important element of effective development.

According to the conclusions presented after the trade fair, speed in plastics projects depends not only on faster machinery. Short communication channels, close integration of development and mould making, and early testing of ideas under practical conditions are also significant. Deckerform reported that the event generated new project concepts and reinforced cooperation with its partners.

Precision and finishing in live operation: Using the modular Catwalk Integral cat staircase, Deckerform, in collaboration with Leonhard Kurz, demonstrated contour-following roll embossing directly at the exhibition stand