Our manufacturing expertise goes far beyond production
Our manufacturing expertise ranges from start-up management to certified project management. After all, a good idea is just the beginning: the production process that turns innovative ideas into marketable products is crucial. Thanks to our patented manufacturing processes, we bring functions and added value together and set new standards in series production.
Our production is characterized by state-of-the-art automation technologies that combine efficiency, precision and sustainability. This not only reduces the carbon footprint, but also ensures the highest quality throughout the entire product life cycle.
In order to perfect our products, we rely on a state-of-the-art test laboratory. We use methods such as preliminary mechanical tests, thermal analysis technology, dynamic component testing and environmental simulations. Get an overview of our processes before, during and after production. All steps are interlinked. This is how we ensure that our molded parts and housing systems made of particle foam reliably meet all requirements, even under the most demanding conditions.
From the idea to the finished product
shaping the future – we do this with structure and passion. Because our mission is to bring innovations to life. With a feel for market needs and opportunities and a passion for innovation, we develop ideas and transform them into individual solutions for you. As application specialists, we accompany you through the entire development process: from the development of new products and materials to the design of innovative tools and devices.
Before production
Our manufacturing expertise is evident even before the actual production of our molded parts made from particle foams begins: Challenges that initially seem unfeasible or applications where particle foam has not yet been utilized are carefully analyzed by our Business Development team. Through our project management and precise process organization, we then ensure smooth implementation of the product design. We also work with highly detailed prototypes and even develop foam moulding tools ourselves.
Individual customer needs, new trends and technological developments are at the heart of our business development. In our think tank, we develop innovative technologies, processes and materials that create completely new possibilities – always with a view to series production and the highest quality. We shape the future of your projects with a passion for innovation and technical expertise.
With our IPMA-certified project management since 2008, we make complex projects plannable, minimize risks, maximize chances of success and optimize overall costs. From the definition of clear objectives to detailed process and cost planning, we lay the foundations for smooth project progress – even before the order is placed.
Since 2015, we have also relied on a process-oriented organizational structure that enables fast processes and customer-focused solutions through interdisciplinary teams. Our project management and process organization are your guarantee for the best possible achievement of all content-related goals – flexible, efficient and precisely tailored to your requirements.
Our product design transforms your requirements into innovative solutions. As a trusted development partner to the industry, we create precise surface and volume designs and implement them consistently in models and tools. We use leading systems such as CATIA V5, SolidWorks and ThinkDesign to realize your visions exactly – in almost all common CAD formats. Secure data management and modern archiving technologies ensure that the data you send to us is protected. Encrypted interfaces are available for secure communication.
Using state-of-the-art CAM/CNC technology, we produce precise prototypes that serve as functional or illustrative models. These prototypes enable rapid field tests, shorten approval times and provide valuable insights for market analysis. In addition, mechanical and physical tests can be carried out and the 3D data set validated, which optimizes the subsequent creation of foaming tools and the need for changes to the series product. Small series can also be realized cost-effectively as prototypes.
Customized foaming tools are essential for the production of moulded parts from particle foams. These tools form the desired contours and ensure consistently high quality over many years. We develop these tools with the highest precision in our in-house tool design department.
Particularly when developing products in-house, we can ideally incorporate and implement your requirements in our own tool design. We use new tool technologies and processes and work continuously on innovation projects, for example to increase efficiency. Together with our long-standing partners in mold construction, we ensure that every foaming tool is precisely specified and optimally matched to the production requirements.
During production
In manufacturing, we bring visions to life with the highest precision. From start-up management, which combines development and production, through series production to the saleable product – every step at RUCH NOVAPLAST is carefully planned and executed.
Our start-up management seamlessly links development and production, ensuring that innovative projects become ready for series production. With state-of-the-art technology, including a universally applicable foaming machine and our own technical foaming facility, we enable material and surface tests to be carried out at the pre-series stage. In this way, we lay the foundation for precise initial sampling and a successful start to production. As a technology leader and problem solver, we develop tailor-made solutions together with our customers – supported by the know-how gained from hundreds of completed projects. Our expertise ranges from new materials and lightweight construction combinations to innovative processes.
Our modern production facilities, including the largest EPP series machine for technical molded parts in Europe, enable the efficient production of molded parts up to over two meters. In combination with technically high-quality tools, series production capability ensured by start-up management and good planning through our order management, we can offer you a high level of supply security with consistently good quality.
We rely on an automated production process for high quantities and maximum reproducibility. RUCH NOVAPLAST ensures that the entire manufacturing, assembly and delivery process is completely transparent and IT-supported – from the receipt of goods to the final inspection of the finished assembly. This enables us to trace all products, including the batch traceability of raw materials and purchased parts.
In our assembly and manufacturing center, we transform individual components into complete systems – whether in the HVAC sector, for model aircraft or construction elements. Here, molded parts made of particle foams are precisely assembled using various processes, while retaining the specific material properties. Other components are seamlessly integrated to complete the system. As a development and system partner, we take on tasks for our customers that they no longer wish to carry out themselves and offer individual solutions for complex requirements.
After production
After production, our laboratory and analytical processes in our in-house materials testing laboratory and a stringent quality management ensure that every product meets the highest standards. Through precise tests and continuous checks during all process steps, we ensure the quality and performance of your products to guarantee reliable and long-term use.
Our extensive materials testing laboratory at RUCH NOVAPLAST enables the precise measurement and documentation of all relevant physical, electrical and chemical parameters – according to your requirements. This enables us to keep project lead times as short as possible. In addition to preliminary mechanical tests, thermal and climatic factors can also be applied to the products. Our laboratory equipment includes a climate chamber for environmental simulations, a programmable laboratory oven, a fire chamber for various flame tests and much more. In addition, we also offer tests on components outside the particle foams. We use these diverse tests to ensure the quality and performance of your products.
At RUCH NOVAPLAST, quality comes first – at every step of the process. From purchasing and development to production and delivery, we meet the highest standards and are certified in accordance with DIN EN ISO 9001.
We use state-of-the-art measuring arm technology to check components for deviations that conventional measuring technology cannot detect. Optical detection and real-time color matching enable us to precisely detect even the smallest deviations. Foaming tools are also scanned in order to compare them directly with CAD data. Thanks to batch tracing, we can track every step of every product, right down to the components and process characteristics. We also test components dynamically – such as EPP housing assemblies for water-bearing devices. With the help of a fully automated leak test stand, we ensure that all products are absolutely leak-proof and meet the highest quality requirements.
Only those who are able to coordinate all individual instruments from development to series production can deliver the best products and leading economic solutions. We have created the appropriate structures for this so that all the processes involved can work hand in hand – for an optimal and effective product development process.
