In an era marked by technological leaps, automotive, medical technology, pharmaceutical, aerospace, and many other industries continue to search for novel solutions to enhance operational efficiency, reduce expenses, and uphold environmental stewardship. Among the solution front-runners is PWF - Doose, a versatile, tool-making firm that transforms conventional manufacturing practices by adopting additive manufacturing (AM), democratizing its accessibility and making it readily available across sectors.

In the last two years, PWF - Doose has made a significant breakthrough by successfully investing in the necessary infrastructure and expertise to scale and integrate AM into its highly industrialized manufacturing lines.

“We discovered that AM’s potential extends beyond prototyping. It is now viable for large-scale production and is well-received by customers keen to optimize their production lines,” says Hartmut Frerichs, EVP sales and marketing and board member at PWF - Doose.

The dynamic team comprises experienced professionals along with young talent to test and validate AM’s transformative potential. With a forward-looking perspective, the company has moved beyond the buzz surrounding AM and taken a grounded approach that focuses on its practical implementations and usability. Performance is prioritized by manufacturing technologically sophisticated AM-based spare parts, assemblies, prototypes, and many other components. This approach ensures the consistent delivery of top-notch products, establishing PWF - Doose as a reliable AM-based tools manufacturer.

Elevating Business Efficiency

AM’s potential transcends boundaries. It has unlocked opportunities in areas like conformal cooling in mold injection tools and spare parts, produced on demand. These aren’t just off-the-shelf products, but specifically crafted parts that meet each client’s requirements. The benefits are manifold— from halved cycle times on production lines and reduced costs to environmental compliance and alignment with a circular economy.

PWF - Doose helps businesses overcome energy, cost, and material consumption challenges, as well as address the performance and environmental issues associated with their products. It manufactures intricate geometries previously unattainable by traditional methods and application-optimized tools that improve production processes and reduce inefficiencies. Using these products, businesses enhance the resource efficiency of their facilities and minimize waste and energy consumption.

For instance, cycle time is a critical determinant in injection molding tools and production lines since it directly correlates to production rate. Businesses can use PWF - Doose’s AM services to develop tools that reduce cycle time. In some cases, clients have slashed cycle times by half, effectively doubling their production capabilities. These tangible improvements have a significant impact on their bottom line.

A quality management team ensures all products are compliant with ISO 9000. PWF - Doose’s quality assurance procedures begin at the concept phase, where its experts meticulously evaluate the technical feasibility and profitability of their products.

This stringent inspection continues in the design stage, where materials are selected, and tolerance levels are specified per client requirements and regulatory compliance. During production and assembly, teams conduct self-checks using the latest IT and measurement technologies. This guarantees extended service lives for its tools—a critical factor in energy-intensive industries like automotive and aviation.

The products offer remarkable advantages in today’s dynamic business landscape, allowing businesses to prototype and shorten time-to-market. Its on-demand services also enhance spare parts availability, setting clients apart from their competitors by enabling them to adapt to market changes and achieve efficiencies.

A Customer-Centric Approach to Delivering Optimal Solutions

PWF - Doose prioritizes customer satisfaction while delivering suitable and optimized products. The company works closely with clients during the development phase, building a solid foundation, discussing product specifications, and exploring the needed equipment. Throughout this iterative process, extensive interactions are conducted with clients to analyze the feasibility and efficiency of their desired products.

Our am tools yield not only lower production costs but also lead to higher profits for our customers. this exemplifies our commitment to delivering operational excellence

“We identify the most effective approach for production, ensuring the tools align seamlessly with their production process,” says Frerichs, exemplifying the company’s commitment to a customized approach.

Following the initial product development and consultation phase, the PWF - Doose team commences the CAD/CAM processes, followed by the fabrication of each AM part. Its product design, engineering, and quality assurance teams constantly communicate with clients to ensure the final product complements their specifications. They check the accurate integration of every additively manufactured component into the final product. Swift delivery to customers allows for the prompt commencement of qualification processes. However, not all customers possess an in-depth understanding of their inherent requirements. Their familiarity with product specifications might not be extensive. Instead, they describe their key priorities.

In response to this limited information, the team seeks to understand their primary concerns and requirements by analyzing critical factors like cost and production processes. The result is a tailored product design that optimally satisfies their needs.

While some businesses may initially opt for standard tools, an increasing number of the company’s clients select customized AM tools. This trend is primarily driven by the commercial attributes of PWF - Doose’s products, which combine exceptional short payback times and precision. Clients quickly reap substantial long-term rewards, making their investment in AM-based products highly lucrative and sustainable.

Throughout the engagement, PWF - Doose functions as a one-stop shop for all AM requirements. Its collaborative approach has earned widespread acclaim for continuously surpassing client expectations, achieving high-end performance, and forging successful manufacturing partnerships.

“Our AM tools yield not only lower production costs but lead to higher profits for our customers. This exemplifies our commitment to delivering operational excellence,” says Frerichs.

Fostering a Circular Economy and Sustainable Future

In light of supply chain disruptions, PWF - Doose took decisive action and established a fast repair cycle service based on AM, particularly, direct energy deposition (DED). Clients can refurbish, reshape, and even optimize worn-out or used parts and tools, giving them a second life. This capability was particularly crucial during the pandemic.

Clients have employed this service to repair and reuse old parts instead of waiting for new ones. Even when specifications for each part were unavailable, the company used 3D measuring technologies to scan the parts at 2 μm accuracy, generating data sets of complex contours needed to make repairs. Cutting-edge optoelectronics, algorithms, and image processing were employed to ensure high precision. A spacious measuring room can accommodate resizable components up to two meters in diameter and weighing up to 500 kilograms. The refurbished tools were like new, with an extended lifetime.

“Amid a production line breakdown, where a critical tool halts the entire process, we can repair that in as short as 48 hours and get the production lines up and running,” states Frerichs.

PWF - Doose also designs tools that can be repaired in an emergency by replacing individual components. By repairing worn-out tools, the firm promotes sustainable practices, fostering a circular economy.

In the healthcare sector, the company is instrumental in reducing plastic waste, manufacturing parts with minimal material, and exploring designs that facilitate recycling. Apart from helping clients become environmentally conscious in their operations, PWF - Doose has undertaken initiatives to reduce its own carbon footprint.

Since 2021, the company has sourced 100 percent of its energy from renewable sources, saving 250 tons of carbon dioxide per year. It procures energy-efficient manufacturing equipment and relies heavily on local supply chains, reinforcing its sustainable practices while simultaneously optimizing throughput times.

Central to its success is its tech-savvy team, skillfully blending fine German craftsmanship with cutting-edge AM services. Although small, the company has remained attuned to dynamic market trends and technological advancements. Its agility facilitates swift adaptation to evolving needs, while its manufacturing expertise allows for the management of a wide range of product specifications. This synergy between innovation, technological acumen, and adaptability defines PWF - Doose.

Recognizing the tremendous growth potential of the ever-expanding 3D printing industry in the U.S., it envisions expanding its operational footprint across the country and helping businesses unleash the full potential of technology. As the future beckons, PWF - Doose joins the ranks of leading innovators who have cracked the code of innovation in additive manufacturing, translating conceptual ideas into tangible realities.