Development expertise from the idea through to high volume production

Development expertise

Whether it’s spring solutions, turned parts, stamped-bent parts or plastic composite parts: at CARL HAAS, you can rely on high-quality components that meet your requirements exactly and are ideally matched to your application.

To ensure cost effective and high-quality manufacturing processes, it is essential to ideally coordinate the individual manufacturing steps and processes. We therefore define individual process steps for every new product and develop the necessary production concept. In addition to the central production processes, we also integrate the accompanying processes.

Our technology and process experts develop the processes continuously so that we can implement sophisticated solutions in any lot size from small runs to high-volume production. Our comprehensive expertise is systematically stored in the group-wide FMEA system, so that all companies in the KERN-LIEBERS group can benefit from it. And the benefit to you: even at the risk analysis stage, we are already able to make informed statements about the feasibility of manufacture of your product.

Working closely together with you, CARL HAAS supports you throughout the entire product development phase.

We use CAD software to adapt draft designs for parts to be developed to the best possible production technology. In our detailed parts drawing, all tolerances are closely examined in terms of economic producibility. The drawing is optimized to ensure that any unnecessary additional work is omitted or replaced by more cost-effective manufacturing processes.

Because we develop the design of the prototype together with you directly on the machine, we can minimize the time from prototype to high-volume production. At the same time, the costs for new developments are reduced.

For the medical engineering sector, CARL HAAS has acquired the EC design examination certificate in accordance with EU Directive 93/42/EEC Annex II Section 4 for the design of guidewires in various different versions.

Thanks to our broad technology portfolio, we can quickly and flexibly combine various processes to manufacture your product solutions with maximum quality and efficiency, even in the face of complex challenges.

The characteristics and costs of your product are determined early, in the development phase of the spring solutions, turned parts, stamped-bent parts or plastic composite parts. That’s why the production-oriented design of each and every individual component in a product is of crucial importance.

We can also manufacture prototypes on series production machines. That means that you have the opportunity to test the first close-to-production prototype samples as early the development and testing phase.

A big plus here is that the technologies and expertise of the entire group of companies is available to draw on. Our experts work closely together in this area.

These technologies include

  • Wire and die sinking
  • Laser and water jet cutting
  • CNC stamping and bending
  • Embossing, stamping, fine blanking in sample frames and in production and test presses
  • CNC milling, turning and grinding
  • All common heat treatment processes and special hardening processes
  • Tumbling (barrel finishing)
  • Honing
  • Steel/ceramic shot peening
  • Wobble riveting, hot riveting, caulking
  • Laser welding
  • Plasma welding
  • Metal kneading
  • Injection molding
  • Stitching (injecting of pins into plastic parts)
  • Wire drawing and rolling
  • Bonding
  • Winding / coiling
  • Cutting to length / cutting
  • Shrinking

CARL HAAS calculates the optimum spring dimensions for you using both standard software and specially developed spring calculation programs, ensuring that you benefit in your spring solution from the optimum spring type, shape and dimensions – the reliable basis for maximum function, service life and cost-effectiveness.

Our spring calculations at a glance

  • Calculation of compression and tension springs in accordance with DIN EN 13906-1 to 2 and quality specifications DIN EN 15800 and DIN 2097
  • Fatigue strength calculation, e.g. Goodman

With our close partnership with material experts among our suppliers, we can incorporate technical customer requirements directly into current raw material developments. As far back as 1928, for example, we developed the patented material Nivarox together with partners.

The broad range of uses of your parts makes particularly diverse demands on the materials we use:

  • Dimensional accuracy
  • Corrosion resistance
  • Temperature resistance
  • Service life
  • Biocompatibility

Simply talk to us about the applications for which your product is used. Our experts will work with you to find the best choice of materials.