"In an emergency—for example, in the event of a tool breakage—we manufacture high-precision stamping dies for our customers within 24 hours," explains HAIL-TEC Managing Director Alexander Renz. Founded in 2004, the high-tech solutions provider from Hohenstein has been a supplier of delicate metal products for medical technology, aerospace, and other demanding industries for years. Currently, 20 employees manage the company's three main pillars: prototype and sample construction, series production, and ultrashort pulse laser service (UKPL).
With the VDWF at the Blechexpo Stuttgart
As a solution provider for prototypes and sample components, HAIL-TEC has been a member of the VDWF (Association of German Tool and Mold Makers) since 2019. Together with the association, the company is presenting cold ablation with ultrashort laser pulses to the public for the first time – at Blechexpo 2019 in Stuttgart, Hall 6, Booth 6108 (VDWF joint booth). Using UKPL technology, HAIL-TEC produces micron-precise molds with surface qualities down to Ra 0,1 µm – for example, stamping inserts and punches made of carbide and hardened steels – extremely quickly.
UKP laser offers new material and design freedom
The femtosecond laser achieves a peak power of more than 100 megawatts with its ultrashort pulses, explains Renz. For components, this means no edge chipping, thermal discoloration, spatter, contamination, or burrs. The ultrashort pulses process components without heat-affected zones or exposed process forces. This increases tool life many times over. "With the USP laser, we realize many applications that were previously only possible using EDM or not at all," says Renz. "Cold" laser ablation is suitable not only for hard metal and tool steel, but also for previously difficult-to-machine materials such as ceramics and PCD diamond, as well as for miniature geometries. This saves time and money, for example, in complex electrode production. And it gives product developers and designers the freedom to always use the right material. Renz cites chemically resistant ceramics or wear-resistant silicon carbide (SiC) as examples.
From sheet metal to prototype
It's not just the USP laser that makes HAIL-TEC fast. "While others are still considering, we're already tinkering with the solution," says Renz, underlining the family business's claim. He sees the perfect implementation of technical challenges under time pressure as his primary task in sample and prototype construction. The high level of vertical integration with a complete technology pool, design, and toolmaking under one roof is a plus: "With our all-round service, we reduce the number of interfaces for clients and can promise binding deadlines," explains Renz. For reliable quality down to the micrometer and nanometer range, HAIL-TEC also offers optical metrology from Alicona as a contract service.
Looking into the future: Microstructuring
"The performance spectrum of the ultrashort pulse laser is enormous – we are currently working on tribological structures and functional surface structures such as the lotus effect. Such hydrophobic, hydrophilic, or antibacterial microstructures on components are possible," says Renz, looking to the future. It certainly won't be long before his clients can benefit from this development.
HAIL-TEC GmbH
Idyllic setting instead of industrial zone: The high-tech job shop HAIL-TEC is located in the heart of the Swabian Alb Biosphere Reserve. Founded in 2004, the company specializes in precise high-tech metal solutions. The industrial service provider's three main areas of expertise are sample and prototype construction, series production, and ultrafast laser service.
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