Technical Plastic Components, Poured Polyamide and TSG Enclosures Kern Kunststoffe / Kern GmbH

Engineering polymer solutions by Kern Kunststoffe / Kern GmbH: large poured polyamide shapes up to 2.5 tonnes, low-stress TSG structural foam hoods, gears, and semi-finished rods. Engineering selection.

Large-Scale Polyamide Poured Components PA 6 G and PA 12 G

Kern foundry produces large-scale polyamide semi-finished shapes and custom components with unit piece weights up to 2.5 tonnes. Utilizing anionic polymerization of lactam melts, the facility manufactures PA 6 G and PA 12 G poured components delivering high crystallinity and minimal internal stress.

Heavy-duty poured polyamide shapes up to 2.5 tonnes
Anionic polymerization of caprolactam & laurinlactam
High-density structural grades PA 6 G & PA 12 G
Centrifugal & form pouring of rings, bushes & plates

TSG Thermoplastic Structural Foam Enclosures and Covers

Components manufactured via thermoplastic structural foam (TSG) technology feature a solid outer skin and a cellular core expanded approximately 10% by blowing agents. This process compensates for volumetric shrinkage and eliminates residual mechanical stress in large protective machine hoods.

Thermoplastic structural foam with solid outer skin
Volumetric shrinkage compensation without sink marks
Integration of internal stiffening ribs & bosses
Complex machine housings, console shells & shields

Polymer Spur Gears and Self-Lubricating Plain Bearings

Engineering dimensioning of polymer spur gears is executed according to the VDI 2545 standard with a 20-degree pressure angle. Thermoplastic polymer plain bearings operate reliably in dry-running conditions without lubrication, eliminating galling, seizing, and rapid abrasive wear.

Spur gear calculations compliant with VDI 2545
Standard 20-degree pressure angle profile design
Maintenance-free dry running without lubricant
Cylindrical spur gears, gear rims & guide bushings

Rigid Integral Skin Polyurethane PUR-IHS Molded Components

Kern manufactures rigid integral skin polyurethane (PUR-IHS) components with piece weights up to 50 kg and surface areas up to 4 square meters. The material combines light weight, exceptional flexural rigidity, high impact resistance, and chemical stability in industrial atmospheres.

Rigid integral skin polyurethane system PUR-IHS
Molded single-part weights up to 50 kg capacity
Component surface areas measuring up to 4 sq meters
Oil-resistant protective hoods, shields & damping units

Precision Multi-Axis CNC Turned and Milled Polymer Parts

High-precision multi-axis CNC turning and milling centers equipped with automatic bar loaders perform complete 6-sided machining of engineering polymer components. The automated process ensures tight dimensional tolerances, fine surface finishes, and repeatable batch consistency.

Complete 6-sided mechanical machining in one setup
CNC turning and milling machines with bar feeding
Precision tolerances for bearing journals & keyways
Custom flanges, bushings, rollers & lead screws

Injection Molding of High-Performance Engineering Plastics

Kern in-house mold toolmaking and automated injection molding presses manufacture technical polymer components weighing up to 16 kg. Production capabilities include void-free thick-wall molding (Dickwandspritzguss) optimized for structural machinery and fluid handling components.

Automated injection molding for parts up to 16 kg
Void-free thick-wall molding Dickwandspritzguss
In-house precision toolmaking and injection molds
Engineering thermoplastics PA, POM, PEEK & PPS

Flexible TPU Elastomer Coupling Spiders for Shaft Couplings

Kern manufactures elastomer spiders from thermoplastic polyurethane TPU with a hardness of 80 Shore A for backlash-free flexible shaft couplings. The spider inserts absorb torsional vibrations, dampen shocks, and compensate for angular, radial, and axial shaft misalignments.

Wear-resistant TPU elastomer coupling inserts
Standardized material hardness 80 Shore A
Backlash-free vibration damping & shock absorption
Compensation of axial, radial & angular misalignment

Engineering Polymer Semi-Finished Shapes and Blanks

The Kern manufacturing portfolio includes extruded and molded semi-finished engineering shapes: rods, plates, hollow tubes, and custom profiles made of polyamide, polyacetal, and PEEK. Blanks are supplied with minimal machining allowances for subsequent CNC turning and milling operations.

Extruded & molded semi-finished engineering shapes
Plates, round solid rods, hollow bars & profiles
Materials PA 6, POM, PET, PTFE, PEEK & PVDF
Minimal machining allowances & low internal stresses

Selecting Heavy-Duty Poured Polyamides PA 6 G and PA 12 G for Machinery

For sliding components and heavy machine guides, special formulations with solid lubricants are provided, lowering friction coefficients and guaranteeing exceptional dimensional stability under cyclic loads.

Design Advantages of TSG and PUR-IHS Structural Foam Enclosures

Instrument housings and protective equipment hoods manufactured using TSG and PUR-IHS technologies combine a solid outer skin with a microcellular core that eliminates volumetric sink marks. This ensures high stiffness, excellent impact absorption, and weight reduction compared to metal assemblies.

Kern Kunststoffe / Kern GmbH and model names are trademarks of their respective owners and are used only to identify the equipment for which we source parts. SpareX is not an official dealer, distributor or representative of Kern Kunststoffe / Kern GmbH and is not affiliated with the trademark owner. Origin, documents and warranty are stated for each item in the quotation.