Fully Integrated Process

From the idea to the final component.

First Contact

We analyse your needs, we define procedures and deadlines together with you and we provide the first solutions.

Research and Development

The design of products can be conducted by our engineers or in co-design with the client.

The Stages of the Project
Based on each project specification, we study and develop non-conventional geometries like co-moulds with highly automated processes, as well as bi-components moulds,sub-assemblies, weldings, resins and post-cure conditioning processes. We further conduct a careful geometric analysis on all our components, keeping in constant communication with our clients’ technical departments.

The Choice of Material
Thanks to its solid experience and knowledge, Ergotech is able to identify the most suitable polymer for each specific project, looking to guarantee the least deformation and the best process stability.

To achieve that, we make use of modern IT tools to simulate the injection process and test the pond filling flow analysis and, if required, we can develop virtual DOE (Design of Experiment) to monitor and understand data, aiming to achieve shared goals.

Rheological analyses and materials study
We use multiple interconnected calculation software to analyse the virtual model as a component made of microelements, calculated and examined through an attentive structural analysis of the product, which takes into account the variables induced by the injection process, starting from the first analysis stage.

 Communicating with the Client
Our engineers keep sharing updates on the development at each stage of the project so to maintain a constant and effective exchange of information with the client.


Designing the Component
The first technical drawing of the thermoplastic component is created by our Research and Development department. This is the starting point for the entire designing and building of the mould, conducted by the Tooling Department and finally used for the production of the components.

Designing the Mould
The components that make the mould are designed using IT tools to test their suitability and efficacy before the final product is released to the client.

Making the Component
The components that make the mould are constructed internally from our Tooling Department using laser-cut and wire cutting machines.

The Assembly
The mould is assembled before moving to the test stage.

Test and Measurament
Once assembled, the mould is tested under production conditions.  The products are measured looking at specifications agreed with the client, using touch-technology as well as CAT scans.

Cycle Repetition
The non-compliant measures are re- analysed to make the required amendments to the components in the mould. The cycle is repeated until a perfect adherence is obtained between the product and its given specifications.

Communicating with the Client
The communication with the client is constant during the entire process. All the process is in-house, so it is possible to carried out efficiently with handling times below the average.


The Production
The production is carried out through our automated systems using 6, 4, and 4-axis robots as well as automated control systems.

Delivery and customer service

Delivery and Customer Assistance
We provide post-sale technical and engineering assistance to let our clients enjoy peace of mind while keeping improving on our components.

From the first contact all the way through production: we assist the client in making the best choices.
Needs analysis, components co-design, internal mould design, in-house production of moulds’ parts.

Rheological and microstructural analysis

In order to design the components and moulds, Ergotech makes extensive use of modern software for virtual rheological analysis; which consists in the study of the deformed material when under stress.

Specifically, the mould-filling process is carried out by identifying the orientation of the fibres and the configuration of the joining lines from the earliest stages of the design. In this way, any potential flaw is identified and addressed prior to producing the product samples.

Design & Co-Design

Starting from the projects’ specifications, unconventional geometries are studied and developed using co-moulding through highly automated processes, bi-component moulding, assembly of subsets, welding, resin treatments and post-cure conditioning processes. A careful geometric analysis is also conducted in continuous dialogue with the customer’s technical offices.

Rheological Analysis & Materials Study, Microstructures


We have several interconnected software which analyse the virtual model as a combination of all its micro elements, thus allowing us to take into account all the variables of a given project.