Product Development
competencies
Engineering with a System
Product development follows a clearly defined process from technical analysis to series release. Design, material selection, simulation and cost evaluation are consistently designed for process reliability, cost efficiency and production readiness. The close integration with the tool shop and production ensures that developments are implemented as production-ready parts from the outset.
Product Development
for Plastic-Injection Molding
In the analysis and feasibility phase, we check component requirements, functions and boundary conditions in order to ensure a production-compatible and economical implementation in plastic-injection molding.
Technical Consulting
In technical consulting, we analyze requirements, functions and conditions of use in order to set the course for an economical and series-ready plastic solution at an early stage.
Feasibility Analysis
- Assessment of design-for-manufacture feasibility
- Assessment of risks, tolerances and process stability
- Validation of production readiness under real manufacturing conditions
Material & Polymer Selection
- Selection of suitable plastics according to function, load and application environment
- Consideration of costs, lifetime and series requirements
- Alignment with tooling concepts and manufacturing processes
Cost & Manufacturability Assessment
The cost and production evaluation creates transparency about investments, unit costs and optimization potential for economic series production at an early stage.
Design, simulation and component optimization are seamlessly intertwined to realize technically robust, economical and series-ready plastic solutions.
Design for Plastics
The component design is consistently developed in accordance with the plastics, taking into account material behavior, tooling technology and production-related boundary conditions.
Component Optimization
- Functional reliability and structural integrity
- Optimization of wall thicknesses and geometries
- Reduction of distortion and use of materials
- Design for series processes and service life
Fill & Warpage Simulation
- Analysis of material flow and filling behavior
- Evaluation of weld lines and air traps
- Prediction of warpage and dimensional stability
- Optimization of cycle times and process windows
Prototypes and validation steps are used for functional safeguarding, component release and the targeted preparation of economical series production.
3D Printing / Prototyping
- Rapid prototypes for evaluating geometry, function and design
- Early identification of design and functional improvement opportunities
Functional test & validation
- Physical testing to verify dimensional accuracy, load-bearing capacity and functionality
- Verification of requirements as the basis for production release
Unit Cost Optimization for Volume Production
- Design and process adjustments to reduce unit costs
- Design for efficient, stable and economical series production
Precision, Engineering Excellence and Process Reliability
The quality of product development at Bretthauer is based on clearly defined development standards, documented decision-making processes and a structured technical validation of every development stage. Design decisions, material selection and process assumptions are clearly documented, checked and approved in order to identify technical risks at an early stage and make them manageable.
This creates a robust development process that ensures reliable handover to tooling and volume production and minimizes downstream adjustments.
Your Development Partner for Plastic-Injection Molding
Proactive Thinking
We analyse requirements holistically, ask the right questions and identify risks before they affect cost, time or quality.
Clarity
We provide clear, well-founded advice – even when solutions need to be adapted or assumptions need to be challenged – to ensure production readiness.
Reliability
We take ownership of technical decisions and actively support projects from initial development through to stable volume production.
Structure
Clear processes, defined interfaces and comprehensible steps ensure security and transparency in the development process.
