Efficiently to the final shape
At Façade Creations, the manufacture of Near-Net-Shapes, also known as “close-to-contour manufacturing,” is a key approach for producing complex components made of high-performance plastics in a resource-efficient and economical way. During production, the blank is given a shape that is almost identical to the final contour, meaning the result is that only a few minor machining steps are required to meet the final specifications.
Façade Creations manages the entire process chain – from developing and manufacturing the material, to producing the Near-Net-Shape blanks, and then on to final machining.
This approach endeavours to reduce material usage and processing costs, shorten production times, and increase overall manufacturing efficiency in a sustainable way. Near-Net-Shape technology is particularly advantageous for combining complex geometries with high-performance plastics, such as PEEK and thermoplastic fibre composites, which are used in the medical technology, aerospace and semiconductor industries.
Get in touch with our Near-Net-Shape team
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Benefits of Near-Net-Shape Moulding
Precision plastic components can be manufactured more efficiently using Near-Net-Shape technology, which offers several advantages.
Material efficiency – less waste, more added value
Conventional machining often results in substantial material loss, because components are machined entirely from solid plastic semi-finished products. In contrast, Façade Creations’ Near-Net-Shape manufacturing relies on preforms that are close to the final contour. This means only minimal finishing is needed, which greatly reduces waste and delivers significant material savings.
Time and cost savings – less processing, faster processes
Close-to-contour prefabrication reduces downstream machine running times, since the machining effort for complex components is significantly reduced. In large serial production in particular, this significantly shortens production times and makes processes more efficient.
Challenging geometries – new scope for design and function
Thanks to Near-Net-Shape processes, Façade Creations is opening up new possibilities in component design. Parts with high precision and complex geometries – which were previously difficult or impossible to produce using methods like injection moulding – can now be manufactured economically. This includes components with undercuts and functionally integrated structures.
The result is maximum design freedom, integrated functions, and high-performance plastic components precisely tailored to your application.
From raw materials to solutions – the Façade Creations One-Stop Shop
At Façade Creations, we bring together comprehensive expertise in plastics processing and a wide range of technologies. Whether it’s injection moulding, direct forming, machining, or other plastics processing methods, Façade Creations carries out all processing steps in-house. This means: single point of contact, consistent process control and a finished end product from a single source – efficient, reliable and precisely tailored to your application.
Near-Net-Shape Processes
Façade Creations can manufacture Near-Net-Shape parts from high-performance engineering plastics using injection moulding, compression moulding, or press sintering (direct forming process). Subsequent final processing, such as cutting threads, drilling holes, or milling to size, can also be carried out in-house. This gives us a resource-efficient, economical, high-performance solution that replaces complex, costly processes and enables the production of complex geometries.
Near-Net-Shape in injection moulding
The blank is injection moulded with Near-Net-Shape accuracy, and then machined according to the specifications required. This process enables the creation of complex structures and undercuts that would not be technically feasible using injection moulding alone. A comparison shows that combining injection moulding and machining results in a more economical, optimised component design than a fully machined plate.
Machining: Functional design, but costly to manufacture.
Near-Net-Shape: Complex, material-saving, weight-reduced design.
Near-Net-Shape in compression moulding
Near-Net-Shape compression moulding is used to produce thermoplastic composite preforms. First, plastic-coated fibre mats, known as semipregs, are cut to size and placed in the mould. Then, they are consolidated and impregnated.
This process is ideal for producing highly stressed, complex, or three-dimensionally curved components that would otherwise require time-consuming milling from fibre-reinforced plates. Near-Net-Shape manufacturing significantly reduces material usage. Unlike milling from a composite plate, Near-Net-Shape compression moulding allows the fibres to be laid in the mould along the defined direction of force. This allows the mechanical reinforcement to be precisely tailored to the expected load patterns during use. These customised composite components are used in medical technology, mechanical engineering, sports, and aerospace.
Near-Net-Shape in direct forming
In the direct forming technology for Near-Net-Shapes, the preforms are made from high-temperature polyimide (PI) plastic.
The powdered material is pressed into blanks that closely match the final shape, which are then sintered. This process can be used to produce parts that have to withstand high mechanical or thermal loads.
Subsequent processing, such as finishing or precise milling, can be carried out at Façade Creations or your own location. This allows for the realisation of material- and time-efficient solutions that are precisely tailored to demanding applications.
Near-Net-Shape Applications
PEEK housing – for CT applications
Material: Made from a natural PEEK material.
Manufacturing: Blank production by injection moulding, machining of joint and inner surfaces, surface finishing, assembly of components.
Retractor – for fixing systems
Material: Made from a black, carbon-fibre-reinforced PEEK composite.
Manufacturing: Contour-accurate production using compression moulding, recesses created directly during the pressing process or by subsequent machining.
Bottle gripper – for handling systems
Material: Made from a graphite-filled polyimide material.
Manufacturing: Production of the blank by direct moulding, milling of specific functional dimensions, thread insertion.
Gear box – for e-bikes
Material: Made from a carbon-fibre-reinforced PEEK material.
Manufacturing: Production of the blank by injection moulding, milling of the gear teeth.
