At Kuteno 2026 in Bad Salzuflen, Deckerform will present a business scope covering product development, tooling and system solutions for complex applications in plastics processing. The company will show how the early integration of tooling expertise into the design process can shorten development cycles and facilitate the transition from a product concept to stable series production. The presentation will be based on two current customer projects, Catwalk Integral and SinuX Flex AG. An additional part of the exhibit will be the company’s offer as the exclusive distribution partner for fully electric injection moulding machines from Toyo Europe. According to Deckerform, the combination of engineering resources, mould design and knowledge of the processing operation is intended to enable the development of economically viable injection-moulded parts, also in the case of demanding geometries and high mechanical loads.
The company positions itself as a development partner linking industrial design with the requirements of reliable series production. At this year’s Kuteno, the methodological approach to such projects is to be shown using specific examples, from strength calculations and assembly verification to the manufacture of production moulds and the selection of machinery solutions. The focus will be on both structural elements exposed to high loads and components requiring very high manufacturing precision and a short implementation time.
Mould technology for structural components for Catwalk Integral
One of the main exhibits will be the modular, UV-resistant cat staircase from the Catwalk Integral brand. In this project, Deckerform was responsible for the comprehensive development of the product at the level of the entire assembly. The scope of work included detailed strength calculations for the load-bearing column elements, prototype construction to verify assembly feasibility, and the identification and verification of defined breaking points in the step assembly. The company then delivered the tooling for the first eight production tools.
An advanced mould for the column element will be presented at the exhibition stand. It uses floating cores and a needle valve nozzle. The mould produces structural parts from glass fibre-reinforced polyamide, PA GF30, with a cycle time of 75 seconds. As the company emphasises, this part is an example of expertise in solutions for mechanically highly stressed parts with complex demoulding directions.
The modular Catwalk Integral cat staircase: Deckerform was responsible for the end-to-end engineering of this UV-resistant assembly. The scope of work included product development, strength calculations, prototype construction and testing
Short development time for a component for SinuX Flex AG
The second example presented at the trade fair will be the “SINUS spring element” from SinuX Flex AG, intended for ergonomic, dynamic sitting. According to the project description, this component requires particularly high precision in tool design, resulting from an innovative upholstery concept and an interlocking gear mechanism used to achieve individual diameters.
The development of this component stage took place mainly in Deckerform’s in-house “plastics workshop”, intended for prototyping, bending tests and material experiments. This practical approach enabled early validation of theoretical parameters. As a result, the time-to-market was significantly reduced. Deckerform states that it needed two weeks for product development and analysis, while mould making, up to the first prototype part, took six weeks. The prior determination of the general basic concept by SinuX Flex AG took about one year.
Agile product development for dynamic sitting: the Sinus spring element from SinuX Flex AG stands out with an innovative upholstery concept. Thanks to agile development at Deckerform, only eight weeks passed from the first idea to the sample part.
System solutions and Toyo Europe injection moulding machines
Deckerform also announces its presence at Kuteno as a supplier of system solutions covering the entire process from product development to efficient series production. In this context, the company will advise visitors on turnkey, energy-efficient production solutions based on fully electric injection moulding machines from Toyo Europe, for which it is the exclusive distribution partner.
According to the information provided by the company, Toyo Europe machines are characterised by very high clamping force precision and durability. Combined with advanced mould designs and precise process control, this is intended to translate into high process stability and minimised cycle times in the manufacture of complex components.
