Many tooling corrections required later have their origin well before mould trials: unsuitable wall thicknesses, overly tight tolerances, difficult demoulding, unfavourable gate positions or a material choice that does not match the geometry.
Engineering at BERGER therefore begins by clarifying the application technically. First, the part function and the genuinely critical dimensions are established. Sealing, snap-fit, guiding or bearing features are then considered, along with visible and functional surfaces. This provides a sound basis for coordinating the part, mould and process.
BERGER grew out of hands-on work in mould trials, tooling corrections and transfer to production. This background still shapes our engineering today: the key question is not only whether a part can be designed, but whether it can be manufactured economically and repeatably at production scale using the actual material, mould and process.
Typical injection moulding factors are considered early: shrinkage and post-shrinkage, warpage, fibre orientation, weld lines, venting, slider and core positions, ejection concept, mould temperature control, parting line and access for inspection.
BERGER defines part function, installation conditions, interfaces, material specifications, relevant standards and customer requirements, volumes and commercial constraints. This provides the technical basis for quotation, engineering and tooling concept.
BERGER assesses geometry, wall thicknesses, tolerances, material behaviour, fillability, demoulding and inspection-relevant characteristics for manufacturability. Critical areas can therefore be identified early and clarified or addressed in the design before tooling begins.
BERGER develops the tooling concept from the part, material and target process. This includes cavity count, gating, parting line, slider and core concept, venting, mould temperature control, ejection, insert handling and other tooling details relevant to production.
Qualified mould-making partners manufacture the moulds. BERGER retains technical project responsibility, coordinates with the mould maker and verifies implementation against part and process requirements. Tooling concept, mould trials, correction loops and transfer to production therefore remain centrally coordinated.
During mould trials, BERGER brings mould, material, moulded part and process together. Dimensional accuracy, surface quality, filling pattern, demoulding, function, process window and any required mould or process corrections are assessed. The focus is not on one good part, but on a production condition ready for approval.
Before production starts, BERGER coordinates approvals, inspection characteristics, process parameters, documentation and handling. This creates a controlled transition from the trialled mould to reproducible production.
BERGER evaluates injection moulding projects technically before mould manufacture, considering part geometry, material, demoulding, tolerance scheme, gating, raw-material specifications, process window and tooling concept as a whole.
The early technical assessment provides sound specifications for the injection mould, machine, mould temperature control, surfaces, ejector concept, marking, scope of supply and mould trials. BERGER prioritises critical characteristics, identifies risks and clarifies necessary adjustments before the project starts.
This means the decision on a mould is based not only on price and lead time, but on a sound technical basis for stable, reproducible production.
For dimensionally accurate functional parts with critical fits, sealing surfaces, guides or bearing features, BERGER assesses the tolerance concept, tooling details, process window and inspection strategy together.
Small and delicate plastic parts require metering, gating, venting, demoulding, handling and inspectability to be considered early in the tooling concept.
Integrated hard/soft combinations, seals and other part functions require a compatible material pairing, defined transition geometry, mould movement and process sequence.
Where thermal, chemical or mechanical demands are high, BERGER matches the material selection – for example PEEK, PPSU, PEI or PVDF – to the part geometry, mould design and process control.
As early as possible – before geometry, material, tolerances and tooling concept are finally defined. At this stage, BERGER can influence manufacturability, cost structure and subsequent process stability most effectively.
