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Progress through Precision

FFT is an ISO-certified company manufacturing a comprehensive range of stampings and cuttings out of both rigid and flexible materials in practically all shapes and formats. We specialise in the precision manufacturing and reliable processing of rigid and flexible parts.

Our customers appreciate us because we provide them with expert advice, engage in open dialogue with them and offer an all-inclusive service. We adapt to new customer preferences and market requirements on an almost daily basis, and our reputation is founded on the excellent reliability, outstanding quality and dimensional precision of our products.

We assess technical feasibility in the quotation phase and suggest alternative materials at the customer’s request. Then, we collaborate with the customer to develop an optimum, tailored solution. Our waterjet cutting machine allows us to produce inexpensive prototypes without any tooling requirements. It also ensures that any necessary modifications can be made at low cost before the tool is engineered.

 

 

Products and materials

The diverse applications of the materials that we process make them important components of countless high-quality industrial products. When optimally used, felt, film, foam, cellular rubber etc. have specific properties that are essential to green innovations in the automotive, electrical, electronics and other industries. They seal, connect, filter, separate, transport, store, insulate, suck in, de-dust , grind, polish, cushion, lubricate and protect. Our dedicated employees ensure that our products satisfy the most stringent requirements of quality and formal precision with the assistance of state-of-the-art processes and dimensionally accurate processing.


Wool felt

Wool felt is one of the oldest textile products in existence. Long before our ancestors learned how to spin and weave, they knew how to make felt. Even today, felt is manufactured according to the same principle, which exploits the natural property of wool fibres ‘felting’ together under the influence of heat, moisture, pressure and rolling. During this multi-stage production process, the wool fibres matte together into an increasingly dense material - felt. Wool felt has thousands of uses. In fact, felt can perform an almost limitless number of functions. In insulates, soaks up liquid and releases it again, grinds, lubricates and protects, absorbs, clads and reduces noise - to mention just a few.

Processing methods
Wool felt is a textile material that can be found in many different areas of the world we live in because it so many useful properties. Taking advantage of this, we manufacture around 10,000 different custom-made products for diverse applications such as grinding, lubrication, protection, absorption, filtering, insulation, cushioning, polishing, sealing, noise reduction, de-dusting, sucking, sound absorption, shock absorption, liquid storage and transportation in our modern processing plant.

Also available in self-adhesive versions or in combination with other materials.

Discover the fascinating colours of wool felt here.

 

Needled felt

Needled felts have become widely established as ‘three dimensional’ filter media for separating solids from gases and liquids. Engineers, chemists and process engineers develop custom-made filters for cold and hot, dry and wet, non-aggressive and aggressive processes that are tailored to the market and optimised for the application. Needled felt can be varied almost infinitely, and each fibre has a range of properties such as heat resistance, chemical resistance or tensile strength. So the choice of fibre depends on the application. Sophisticated manufacturing technology – from needling to finishing – creates products that are perfectly tailored to specific applications.

Processing methods
Synthetic fibres are used to create custom-made precision felts for diverse applications in the highest levels of purity, with excellent chemical, thermal and mechanical resistance. Their properties, some of which are unique, make them suitable for extreme applications such as:

•    High strength textiles for protective garments
•    Materials in computers
•    Precision parts in medical devices
•    Seals in household machines
•    Fire-resistant textiles for cars and aircraft

Needled felts have become essential in countless applications, and it is incredible just how many industrial and everyday uses there are for wool felt and needled felt. They may not always be visible, but they’re definitely indispensable!

Also available in self-adhesive versions or in combination with other materials.


PTFE needled felt

PTFE needled felt is a heavy duty, thermoset needled felt with a PFTE surface coating. The coating gives it excellent slip properties and makes it extremely durable.

Processing methods
We produce PTFE needled felt for various automotive applications (e.g. squeegees for car wrapping).

Nonwoven

ISO 9092 defines ‘nonwoven‘ as a manufactured sheet, web or batt of directionally or randomly orientated fibres.  In nonwovens, the fibres are bonded either by cohesion using chemical bonding agents, or thermally using calendaring technology. Nonwovens manufactured with state-of-the-art production equipment are smart textiles that can be adapted to new requirements in terms of fibre material, production technology and finishing method. Fashion garments are shaped with feather-light nonwoven interlays, and nonwovens are also indispensable in many technical applications.

Processing methods

We manufacture the following nonwoven products:

•    Mouldings
•    Cuttings
•    Rings
•    Strips
•    Discs

Nonwovens can be found in filters or household vacuum cleaners, and they are also used in engine hood liners for noise absorption.

They are also available in self-adhesive versions.


Felt cloth

Felt cloth comes in more than 50 brilliant colours and we encounter it in all kinds of everyday situations - in shop window decorations, on trade fairs stands and in cutlery canteens. Felt cloth is also an excellent craft material because it can be used to make so many things. It is also a very eco-friendly material because it is completely biodegradable! 

Processing methods
Felt cloth is a simple and attractive material that comes in a wide array of colours. We manufacture the following products in felt cloth:

  • Strips
  • Rings
  • Discs
  • Cuttings
  • Mouldings and custom parts

Naturally, felt cloth is also available in self-adhesive versions or in combination with other materials.

Discover the fascinating colours of felt cloth here.


Foams

Polyurethane foams (PUR foams) are manufactured on the basis of polyether, and polyester foams are manufactured by reacting diisocyanates and polyols. Foam products with different properties are produced by way of the targeted selection of raw materials, catalysts and stabilisers, plus a special process design.
Foam manufacturing necessitates the very purest of raw materials, extremely precise processing technology and experience-based know-how. Thanks to their excellent properties, specialist foams have now become established in applications for which other materials were used in the past.  Supplying new solutions for this continuously growing market is both challenging and rewarding.

Processing methods
Today, our portfolio includes more than 200 different types of foams in different densities and colours. They are available in the following variants and for the following applications:

•    Slabs
•    Reels
•    Strips
•    Rings
•    Discs
•    Cuttings
•    Mouldings and custom parts
•    Upholstery and bedding
•    Hospital & healthcare
•    Filtration
•    Ink pads
•    Acoustics and insulation
•    Presentation packaging
•    Packaging
•    Engine compartment acoustics

All articles are available in self-adhesive versions or in combination with other materials.


Films

Hostaphan® (polyester film)
is a film made of polyethylene terephthalate with excellent physical properties. It is made from the same raw material as the well-known Trevira-brand film,  biaxially oriented and thermoset.

Kapton® (polyamide film)
unites a unique combination of properties that have never before been available in any polymer film material. Kapton® retains its outstanding physical, electrical and mechanical properties within a broad temperature range and, as a result, this polymer film has opened up brand new design and application possibilities. Kapton® is particularly useful in applications with high operating temperatures.

Teflon® (PTFE) film (virginal)
has an exceptionally smooth surface. It is not an elastomer, but a very rigid polymer with optimum chemical resistance in a temperature range of approx. -180 °C to approx. +260°C. Teflon® is physiologically harmless, anti-adhesive, completely resistant to aging, doesn’t absorb moisture and has a low friction coefficient. It is predominantly used in laboratory and chemical apparatus.

PTFE glass fabrics
are made of woven fibreglass impregnated with PTFE. They are designed in different grades and their properties depend on the type of woven fibreglass and the level of PTFE impregnation. The resulting surface finishes extend from fabric weave impression to super smooth.

Processing method
We manufacture the following products from Hostaphan® , Kapton® , Teflon®  (PTFE) films:

  • Sheets
  • Tapes
  • Cuttings
  • Stampings

They can have one self-adhesive side if required.


Cellasto® cellular Vulkollan

Cellular Vulkollan (Cellasto®, polyurethane, elastomer) is a microcellular polyurethane elastomer. No foaming agent is used to create the cellular structure, so it pollutant free which simplifies product recycling. The elastomer is manufactured in different densities, ranging from 350 kg/m3 to 650 kg/m3 and it can be supplied in blocks and slabs.

Processing methods
We use our modern waterjet cutting equipment to produce mouldings, rings, strips etc. according to customer drawings or specifications from cellular Vulkollan (Cellasto®, polyurethane, elastomer). Semi-finished products are transformed into finished products with the following mechanical processing methods:

  • Drilling
  • Milling
  • Cutting
  • Stamping
  • Waterjet cutting

Foam rubber

Foam rubber is either natural and/or synthetic rubber (e.g. chloroprene, Buna, EPDM, silicone or fluorinated rubber) that is manufactured with a foaming agent to create an air-filled matrix structure. This ideally unites the raw materials in the special structure. Foam rubber is porous on the inside but has a non-porous outer skin. It can be processed into various shapes, demonstrates excellent dimensional stability and unites outstanding sealing properties with elastic softness.

The foam rubber discs that we make are patterned on both sides. They can also have self-adhesive surfaces. We have a modern machine park for the production of cuttings, rings, discs, strips and mouldings in foam rubber.

Our foam rubber range includes:

•    Natural rubber (base material NR)
•    Chloroprene rubber (base material CR)
•    Buna (base material SBR)
•    Nitrile rubber (base material NBR/Perbunan®)

Processing methods

•    Punching
•    Cutting
•    Waterjet cutting


Cellular rubber

Cellular rubber is a closed-cell expanded rubber, so it is water, gas and air-impermeable. It is manufactured in blocks that have an outer skin due to the production process. Although open-cell rubber needs an almost impermeable production skin, with cellular rubber that is irrelevant because all of its cells are completely separate entities.

The original blocks are split into thinner sheets. Two of the sheets cut from each block have a skin on one side, while the sheets in between have no skin on either side. Various products can be made from the cellular rubber sheets, e.g. panels, reels, strips, rings, discs, cuttings, mouldings and custom parts.

They are also available in self-adhesive versions.

We process the following in-house:

•    Natural rubber (base material NR/SBR)
•    Chloroprene rubber (base material CR)
•    Synthetic rubber (base material: EPDM)

Due to its softness and elasticity, cellular rubber is ideal as a sealing material when only low clamping forces are possible and different gap widths have to be sealed. Since each cell is a separate entity, cellular rubber is also impermeable on the cut surfaces.

Shrinkage is a phenomenon that occurs in all closed cell products due to their structure and it cannot be avoided. However, it can be prevented to some extent by artificially ageing the cut sheets before final processing. In this process, the admissible tolerances for all dimensions under all circumstances also have to be taken into consideration. The tolerance for cellular rubber  is specified in the DIN 7715 P3.

Processing methods

•    Drilling
•    Milling
•    Cutting
•    Stamping
•    Waterjet cutting


Soft rubber

There are some things that cannot be substituted by anything else. One of those is natural rubber. When vulcanisation was discovered around 170 years ago it became possible to convert plastic natural rubber into elastic vulcanised rubber. Today, vulcanisation is a highly specialised technology. Although natural rubber is indigenous to the rain forests, it is only ever harvested from rubber plantations. Then it is shipped to Germany in bales.

There are many different types of rubber, and the properties of natural rubber are supplemented by synthetic rubbers with various formulations. Chemists and engineers have developed hundreds of these formulations covering all requirements of elasticity, dimensional stability, swelling, temperature stability, surface properties and hygiene. We manufacture a wide range of products for practically all sectors of industry on our state-of-the-art production machines.

Processing methods

We process the following in-house:

•    Natural rubber (base material NR)
•    Buna (base material SBR)
•    Silicon rubber (base material MVQ)

Also available in self-adhesive versions or in combination with other materials.


Polyurethane/D44

Type D44 polyurethane is a polyester-based PUR elastomer with a very good cost-performance ratio and excellent all-round properties. Its high structural strength combined with good elasticity and low susceptibility to abrasion have opened up a broad range of applications for this type of material. An overview of the advantages of D44 polyurethane:

•    Impressive properties
•    High abrasion resistance
•    Good damping
•    High tensile strength
•    Colour stability
•    Hydrolysis-stable
•    Resistant to ozone and UV light
•    Very low wear-and-tear
•    High elasticity
•    High impact resistance
•    Softener-free
•    Resistant to mineral oils and fats
•    Shore A values of 35 to 98

Processing methods

The permanent optimisation of the polyurethane formulations enables us to adapt this material to diverse customer requirements. So polyurethane is extremely versatile in use. Applications include:

•    Wipers
•    Damping elements
•    Spring elements
•    Pump membranes
•    Squeegees
•    Cutting mats
•    Wear plates
•    Stop buffers
•    Seals
•    Coupling elements
•    Wheels and castors
•    Snow plough blades


Silicone

The silicone we use is FDA-compliant and predominantly used in the food and automotive sectors. It can be supplied in various Shore hardnesses and thicknesses.

Processing methods

Silicone can be processed with any cutting equipment, i.e. our waterjet cutting machine, our stamping machines or our cross cutters.


LDPE

LDPE is low-density polyethylene. It is often used for sealing applications in the printing industry, and we can supply it in different colours and densities.

Processing methods

LDPE is mainly processed on the waterjet cutting machine.


Processing methods

Cutting and stamping

FFT has been producing stampings and cuttings for 30 years now – as ready-cut products, reels or strips in any length, width or thickness! We are a potential partner to retail and manufacturing customers with cuttings requirements.

Our machine park is designed for both large and small production runs. Stampings can be produced on the basis of sketches or drawings. Most of the round stampings are produced with FFT’s own tools, which means that the customer doesn’t have to pay any tooling costs. FFT is a strong partner to manufacturing and retail customers with stampings requirements.

Contact FFT next time you need cuttings or stampings.

Waterjet cutting

Problematic materials cannot be accurately processed with conventional machines. FFT has found an unconventional solution to this problem: waterjet cutting machines. Waterjet cutting has been making a very important contribution to the FFT product portfolio for many years now.

The advantage of waterjet cutting is obvious:

There are no tool engineering costs because the cuttings are made with CAD programs. Waterjet cut products can be manufactured in all dimensions with extremely narrow tolerances.

Take advantage of FFT’s waterjet technology!

Self-adhesive lamination

Around 80% of the products that FFT manufactures are self-adhesive either on one or both sides. Many things have changed in the adhesives sector since the early days. Today semi-permanent and permanent adhesives are available for different requirements, e.g. as an assembly aid.

FFT also offers customers solutions for self-adhesive products with special applications.

 

Contract manufacturing

Contract manufactured cuttings, stampings and waterjet-cut products

We contract manufacture products to customer specifications and preferences! Our comprehensive range of production technologies includes cutting, stamping and waterjet cutting.

Waterjet cutting is suitable for both small-scale prototype production runs and large-scale production runs. We can also produce samples very quickly on the basis of customer DXF files, and use customer sketches to create suitable CAD programs. Not only is the cutting quality unsurpassed, the cut material isn’t exposed to any thermal loads. It is simply penetrated by water travelling at many times the speed of sound.

Take advantage of FFT’s diverse contract manufacturing options!



Service

We enjoy the challenge of special customer requirements and we can produce technical components in a cost-optimised process to specification. We specifically develop the programs for CNC-controlled machines from customer drawings, files or samples.

When thickness is a crucial parameter, we use our application-specific know-how to split sheet products within the narrowest of tolerances.

This level of precision is appreciated by customers in many different industries, such as automotive, glass construction, window construction, orthopaedics equipment, heating engineering, furniture, bakery equipment, mechanical engineering, car wrapping, car wrapping accessories, footwear and electronics. Designers with innovative and unconventional ideas also come to us for technical support.

This level of precision is appreciated by customers in many different industries, such as automotive, glass construction, window construction, orthopaedics equipment, heating engineering, furniture, bakery equipment, mechanical engineering, car wrapping, car wrapping accessories, footwear and electronics. Designers with innovative and unconventional ideas also come to us for technical support.

We have been DIN ISO 9001-certified since 2004. We guarantee consistent quality with continuous dimensional accuracy checks and work process optimisation.

About us

FFT is now a second-generation, family-owned business that has been producing cuttings and stampings from rigid and flexible materials since 1986. Our company is located in the beautiful Neanderthal region of Germany. We have a young and enthusiastic team that is committed to flexibility, speed and transparency and our customer base includes both private individuals  and commercial customers.

With the help of our motivated and loyal workforce we have managed to build a good reputation in our market, and we enjoy trusting and dependable partnerships with our customers and suppliers. Two key aspects of our responsible corporate management policy are the conservation of resources and the protection of the environment.

Our suppliers share our quality mind-set, so we know we can rely on getting best quality raw materials and perfect machine technology. Constructive criticism, receptiveness to suggestions and respect are the basis of our excellent, long-standing relationships with our suppliers.

FFT – Filz Folien Technik GmbH

Contact

Phone: +49 2104 91410
Fax: +49 2104 914141
Email: info@fft-mettmann.de

Site Notice

Location
FFT Filz-Folien-Technik GmbH
Industriepark Ost
Industriestr. 11
40822 Mettmann
Germany

Managing Director
Frank Knoch
VAT ID No.: DE121636252
Commercial Register No.: HRB-Nr. 12912
District court: Wuppertal

Concept and Implementation
Freitag! Werbeagentur und Verlag GmbH, Wuppertal

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