Development

Do you have a great product idea? Or are you looking for an innovative method or a highly efficient manufacturing process? We are ready to help and provide the solutions you need! KH’s development department has successfully tackled many tough challenges—such as overmolding glass and metal or the energy-efficient cleaning of exhaust air from paint shops. We look forward to the challenge!

Scope of Services

It’s best to involve us in your project from the very beginning; we’ll be happy to assist you with:

  1. Design Development
  2. Product Development
  3. Prototyping
  4. Tool Development
  5. Process Development
  6. Project Development

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Medical devices from A to Z – worldwide with KH

Our single-use endoscope is a prime example of our capabilities: The entire manufacturing process was developed and implemented by KH—from the mechanics within the handle to the labeling and shipping of the finished assemblies. It involves multiple variants, up to 12 different plastic components (including several two-component parts), 15 purchased components, and cleanroom assembly. As a CMO/CDMO, we execute medical projects across our five locations on three continents.

Engineering

Do you already have a vision of your product? Often, slight adjustments are needed to ensure efficient production via injection molding. We also develop the internal components according to your specific requirements and specifications.

 

Tool shop

We manufacture molds in-house—ranging from micro-injection molds to those for larger-volume parts. With multi-component technology, filling simulations, CAD, CAM and CNC capabilities all integrated, our workflows are streamlined and efficient.

 

(Cleanroom) Injection Molding

Micro-injection molding systems with cleanroom capabilities produce tiny plastic parts weighing as little as 0.004 grams and with wall thicknesses as thin as 0.1 millimeters. Of course, we can also handle larger parts.

(Cleanroom) Assembly

Complex assembly operations under a microscope: At our European KH locations, we operate Class 7 and 8 cleanrooms staffed by experienced employees. For other products, we have also operated fully automated assembly lines for extremely high production volumes.

 

Packaging

Careful packaging of the endoscopes in blister packs. A specialized sealing machine seals the Tyvek pouches. Labeled directly in the cleanroom, the endoscopes are then sent for sterilization in additional outer packaging.

 

Full Service

Thanks to our expertise and extensive in-house manufacturing capabilities, we are your ideal full-service partner. Our services range from the global sourcing of purchased components to validation.

Innovative Applications

Our products speak for themselves – even if innovations aren’t always apparent at first glance. Behind every product lies a sophisticated technical solution developed in-house at KH. Do you have a project that sounds almost impossible? Just ask us.

A window regulator with a seamless surface and touch functionality? No problem with 3D IML, printed conductor paths and electronics integrated directly into the component.

Overmolding ultra-fine, flat filter mesh with PEEK—without warping or unwanted melting. A success! The intake filter is resistant to aggressive media and is used in laboratory settings to filter out suspended particles.

Batch size one: An emergency button required individual QR codes integrated into the housing component. Digital printing and in-mold labeling made it possible.

Thinking outside the box

At KH, R&D isn’t just about injection moulding and toolmaking – our engineers also work on environmental, electronic and surface-treatment issues. The results are often so groundbreaking that they can be patented.

SmartAir

Better and more cost-effective: SmartAir purifies exhaust air (from paint shops, the chemical industry, hospitals, etc.) using a modular, low-temperature process that is more cost-effective than existing technologies.

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Sealed Surfaces

Fewer gaps mean less contamination. Sealed surfaces are highly attractive for areas with stringent hygiene requirements. KH creates them using IML and integrates the necessary electronics directly into the component.

Antimicrobial surfaces

Surfaces that are touched by many can transfer germs. An antimicrobial feature prevents this. We would be happy to inform you about the various processes.

Glass Overmolding

A genuine dream team: highly transparent glass and flexible, malleable plastic. KH positions freely floating glass plates fully automatically into the tool and encapsulates them on the narrow side. The result is a type of lense with “window frames”. With the newly developed technology, previously unrealizable applications are now made possible. read more

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