OFFER
Comprehensive support in tooling projects
Precision, experience, reliability
DISCOVER OUR OFFER
Bänninger-Formtechnik specialises in the design, manufacture and servicing of tools for the processing industry. We deliver complete tooling projects — from the analysis of documentation and technological assumptions, through 3D/2D design, the selection of technical solutions, the manufacture of components, assembly and commissioning, all the way to supporting the client during tool operation.
Our offer includes injection moulds, stamping dies, blanking dies, die-casting moulds, inspection and measuring tooling, tool reconditioning, EDM electrodes, special tools and the distribution of standard components. By combining design experience, production facilities and a practical knowledge of technological processes, we can support clients both on new projects and in the modernisation and maintenance of existing tools.
Our offer includes injection moulds, stamping dies, blanking dies, die-casting moulds, inspection and measuring tooling, tool reconditioning, EDM electrodes, special tools and the distribution of standard components. By combining design experience, production facilities and a practical knowledge of technological processes, we can support clients both on new projects and in the modernisation and maintenance of existing tools.
We design and manufacture injection moulds for producing plastic parts, both for simple technical components and for more demanding precision components. We make single- and multi-cavity moulds, cold- and hot-runner tools, slider moulds, overmoulding solutions and moulds for two-component parts.
We begin every project with an analysis of the part geometry, the material, the production assumptions and the quality requirements. On this basis we choose the mould layout and the method of filling, venting, guiding, cooling and ejecting the part. Depending on the client’s needs, we can also support the project at the stage of optimising the part for injection-moulding manufacturability.
Our goal is to deliver a tool that is stable in production, easy to operate and prepared for a long service life. We provide technical support during trials, commissioning and subsequent series production.
We begin every project with an analysis of the part geometry, the material, the production assumptions and the quality requirements. On this basis we choose the mould layout and the method of filling, venting, guiding, cooling and ejecting the part. Depending on the client’s needs, we can also support the project at the stage of optimising the part for injection-moulding manufacturability.
Our goal is to deliver a tool that is stable in production, easy to operate and prepared for a long service life. We provide technical support during trials, commissioning and subsequent series production.
We design and manufacture moulds for high-pressure die casting. These are tools that work under demanding thermal and mechanical conditions, which is why we pay particular attention to the correct design of the forming system, venting, cooling, guiding and the durability of the working elements.
Depending on the project assumptions, we prepare moulds with sliders, cores, interchangeable inserts and solutions that make the tool easier to operate and service later on. We analyse the casting geometry, the parting locations, the gating system, potential risk areas and the requirements for surface quality and dimensional repeatability.
We also offer support during technological trials, mould commissioning and the introduction of corrections resulting from the first castings. Our task is to prepare a tool that is not only structurally correct, but above all effective and stable in production.
Depending on the project assumptions, we prepare moulds with sliders, cores, interchangeable inserts and solutions that make the tool easier to operate and service later on. We analyse the casting geometry, the parting locations, the gating system, potential risk areas and the requirements for surface quality and dimensional repeatability.
We also offer support during technological trials, mould commissioning and the introduction of corrections resulting from the first castings. Our task is to prepare a tool that is not only structurally correct, but above all effective and stable in production.
We make tools for metal forming and sheet-metal cutting, including conventional stamping dies, blanking dies, progressive tools and transfer tools. We prepare solutions for parts requiring blanking, bending, drawing, calibration and other technological operations carried out on presses.
The scope of work may include part feasibility analysis, development of the process concept, preparation of blank developments and successive operations, 3D/2D tool design, manufacture of parts, assembly, trials and corrections after the first stamping runs. In doing so we take into account the type of material, the sheet thickness, the required tolerances, the grain direction, the method of strip feeding and the requirements for tool durability.
Thanks to our experience in designing and building tools for series production, we can support clients not only in building a new tool, but also in optimising an existing production process.
The scope of work may include part feasibility analysis, development of the process concept, preparation of blank developments and successive operations, 3D/2D tool design, manufacture of parts, assembly, trials and corrections after the first stamping runs. In doing so we take into account the type of material, the sheet thickness, the required tolerances, the grain direction, the method of strip feeding and the requirements for tool durability.
Thanks to our experience in designing and building tools for series production, we can support clients not only in building a new tool, but also in optimising an existing production process.
Before an electrode goes to the die-sinking EDM machine, it must pass through three key stages: design, manufacture and measurement. This is exactly how we approach electrode production — not as a single machining operation, but as a complete technological process that directly affects the quality of the subsequent erosion.
In the EDM process, the electrode acts as the forming tool. Its geometry, surface quality, manufacturing accuracy and correct referencing determine the result reproduced in the steel. That is why every electrode, before it is used in the erosion process, undergoes dimensional inspection on a coordinate measuring machine at our facility.
We make graphite electrodes prepared to work under conditions corresponding to the real erosion process. We work on graphite cooled with dielectric — the same medium in which the electrodes will later operate on the die-sinking machine. This makes it possible to increase process stability, reduce the risk of damage and maintain high manufacturing accuracy.
We offer a complete service in the design and production of EDM electrodes — both for the tools we make ourselves and as a separate service carried out on the basis of the client’s documentation. Every electrode is prepared in accordance with the assumed geometry, erosion technology and quality requirements.
As part of the service we provide precisely made graphite electrodes, CAD models and manufacturing documentation, CMM dimensional inspection and measurement reports confirming that the manufacture conforms to the project assumptions.
In the EDM process, the electrode acts as the forming tool. Its geometry, surface quality, manufacturing accuracy and correct referencing determine the result reproduced in the steel. That is why every electrode, before it is used in the erosion process, undergoes dimensional inspection on a coordinate measuring machine at our facility.
We make graphite electrodes prepared to work under conditions corresponding to the real erosion process. We work on graphite cooled with dielectric — the same medium in which the electrodes will later operate on the die-sinking machine. This makes it possible to increase process stability, reduce the risk of damage and maintain high manufacturing accuracy.
We offer a complete service in the design and production of EDM electrodes — both for the tools we make ourselves and as a separate service carried out on the basis of the client’s documentation. Every electrode is prepared in accordance with the assumed geometry, erosion technology and quality requirements.
As part of the service we provide precisely made graphite electrodes, CAD models and manufacturing documentation, CMM dimensional inspection and measurement reports confirming that the manufacture conforms to the project assumptions.
We make gauges and inspection and measuring tooling intended for the control of series-produced parts. These are solutions that support a fast, repeatable and unambiguous assessment of a product’s conformity with the requirements of the technical documentation or the client’s functional assumptions.
We design gauges for checking dimensions, hole positions, shape, contour and the functional features of a part. Depending on the need, these can be simple workshop gauges or more elaborate inspection stations adapted to a specific production process.
We make the tooling together with technical documentation and — if required — an inspection instruction. This gives the operator a clear working tool and the quality department a repeatable method of verifying the part.
We design gauges for checking dimensions, hole positions, shape, contour and the functional features of a part. Depending on the need, these can be simple workshop gauges or more elaborate inspection stations adapted to a specific production process.
We make the tooling together with technical documentation and — if required — an inspection instruction. This gives the operator a clear working tool and the quality department a repeatable method of verifying the part.
Distribution of standard components for injection moulds and stamping dies. We are the sole Polish distributor of high-quality products from the French manufacturer MDL and the Italian company Nuova Ret.
HOW WE WORK
CONSULTATION AND ANALYSIS
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DESIGN AND ENGINEERING
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PRODUCTION AND INSPECTION
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TESTING AND OPTIMISATION
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DELIVERY AND SUPPORT
FREQUENTLY ASKED QUESTIONS
Do you only handle design, or tool manufacturing as well?
We offer complete project delivery: from technical analysis, through 3D design and 2D documentation, to the manufacture of components, assembly, commissioning and support in implementing the tool into production. As a result, the client receives not just documentation, but a ready technological solution.
What information is needed to prepare a quotation?
To prepare a reliable quotation, it is best to send 3D and 2D documentation with tolerances, information about the material, the planned production volume, the machine on which the tool is to be commissioned, any technological assumptions and any requirements regarding standards, quality control or documentation. If full data is not available, we can begin the analysis with the materials at hand and indicate what else we need for a complete quotation.
In which formats can documentation be sent?
Documentation can be sent in any neutral CAD format, such as STEP, IGES or Parasolid X_T. We also work with the native CAD file formats of SolidWorks, Siemens NX and Autodesk Inventor. For requests for quotation, please send a 3D model together with a 2D technical drawing if it contains tolerances, material requirements, surface markings or other relevant technological information.
Can you sign an NDA?
Yes. We understand that tooling projects often involve new products, confidential documentation or solutions covered by trade secrets. At the client’s request, we can work under an NDA before starting a detailed analysis of the documentation.
Do you carry out part feasibility analysis?
Yes. At the enquiry analysis stage, we check the part geometry for manufacturability, possible mould splits, opening directions, undercuts, ejection, injection points, venting, cooling and potential production problems. For stamping and blanking dies we analyse, among other things, the product shape, the process sequence, the feasibility of the operations and the material requirements.
Do you help optimise the part design?
Yes. If the part geometry may cause technological problems, we propose possible design changes. This concerns, among other things, wall thickness, radii, draft angles, ribs, undercuts, sealing surfaces, tolerances and locations critical for assembly and inspection. Our goal is not only to make the tool, but also to improve the stability of subsequent production.
Do you make hot-runner injection moulds?
Yes. We design and manufacture injection moulds with hot-runner systems. We use proven solutions from renowned hot-runner system manufacturers or solutions specified by the client, if the project requires the use of a particular supplier.
Do you handle reconditioning and modification of existing tools?
Yes. We carry out repairs, reconditioning, modifications and the adaptation of existing tools to new production requirements. We can help, among other things, with design changes to the part, problems with moulded-part quality, wear of working elements, play, cracks and problems with guiding, ejection or cooling.
Can you work from documentation supplied by the client?
Yes. We can make a tool on the basis of the client’s documentation or take over a project at a chosen stage. However, we check the documentation for feasibility, completeness and potential technological risks. If we notice ambiguities or possible problems, we report them before starting work.
Do you offer technical support after the tool is completed?
Yes. We provide technical support related to commissioning, modifications and the further operation of the tool. In practice this means the possibility of consultations, making corrections, manufacturing spare parts, analysing production problems and supporting the optimisation of the tool’s operation.
Do you produce the tool’s technical documentation?
Yes. We have our own design office, so preparing technical documentation is an integral part of our work. We produce 3D models, 2D documentation, working drawings, bills of materials and the documentation needed for manufacturing, assembly, commissioning and later servicing of the tool. We adapt the scope of documentation each time to the type of project and the client’s requirements.
Can you carry out a tool trial?
Yes. For stamping tools we are able to carry out trials on our own presses, which lets us verify the tool’s operation before handing it over to the client. We have a press of 2000 × 1200 mm with a pressing force of 400 tonnes and a press of 1000 × 1000 mm with a pressing force of 100 tonnes. For injection moulds, depending on the project requirements, we can arrange trials at our proven technological partners. We also offer technical support during trials, commissioning and implementation of the tool directly at the client’s site.
What does the tool lead time depend on?
The lead time depends on the type of tool, the complexity of the design, the number of components, the availability of materials and standard parts, the scope of machining, the heat-treatment requirements, coatings, trials and any changes introduced during the project. After analysing the documentation, we determine a realistic completion date.
Do you use standard components?
Yes. In our projects we use standard components from renowned manufacturers, according to our recommendation or the client’s indications. We are also a distributor of MDL and Nuova Ret standard parts.
Do you carry out projects for international clients?
Yes. We serve clients from Poland and from international markets. We work in a technical environment in which communication, documentation and project arrangements can also be conducted in English.
What sets us apart?
What sets us apart is our comprehensive approach to delivering new tooling projects. We do not limit ourselves solely to making a tool according to documentation — we support the client already at the stage of technical analysis, concept, design, manufacture, trials and implementation into production. We focus on a partner-like and transparent cooperation based on understanding the client’s real production needs. We care not only about delivering a finished tool, but above all about making it stable, functional and matched to the conditions in which it will operate. We build long-term business relationships based on trust, responsibility and technical support. That is why the client receives from us not only a product, but also a committed partner who helps to safely go through the successive stages of project implementation.