Pattern shop
The foundation of a strong product
In BIRN’s pattern shop, the foundation for cast components takes shape. This is where traditional craftsmanship meets advanced technology. Every single detail is carefully planned and executed with the highest level of expertise and precision.
Our team of experienced specialists ensures a deep understanding of the processes and guarantees consistently high quality.
From concept to product
Before a pattern is ready to be produced, our customers’ ideas are transformed into drawings in our engineering department. These drawings are then turned into steel plates, which are cut and shaped with advanced CNC milling machines. The result is assembled into accurate custom metal casting molds that will later be used in production.
The patterns are then carefully mounted and fine-tuned in the pattern shop until every detail is in place. Before they are released for full-scale casting, the patterns undergo strict quality checks and trial runs to ensure reliability.
Patterns in all shapes and sizes
At BIRN, we produce patterns in a wide range of sizes and forms – from smaller parts, such as components for spinning bikes, to larger elements for the truck industry.
To ensure long-term value for our customers, we store many metal molds for casting in our high-bay warehouse. These patterns represent a significant investment, which is why we focus on maintaining and protecting them to extend their lifetime. When a customer needs to reorder a component, we can quickly retrieve the existing pattern.
We also provide mold making and maintenance services to keep existing patterns in top condition, ensuring they continue to meet the high standards of quality and precision. If necessary, we can adapt the patterns to fit the customer’s current production requirements.
This approach ensures that our customers’ investments in casting molds are protected, and that the path from reordering to finished components is as efficient and smooth as possible.
Craftmanship and technology
Although the techniques in our pattern shop are rooted in long-standing traditions, we combine this craftsmanship with modern technology. By using machine power in several stages of pattern making, we free up resources for the delicate manual work that requires human precision. This allows us to focus on the accurate assembly of even the smallest components on the mold.
The quality of the pattern has a direct impact on reducing material waste, optimizing the casting process itself, and enabling efficient post-processing of the final component. In other words, precise cast prototypes start with precise patterns.
"Together, we strive to create products of the highest quality, so our customers receive the best possible results. That’s why our pattern shop is the foundation of BIRN’s ability to produce components that live up to customer expectations. The shared effort across all departments is crucial."
- Carsten Wiese, Foreman at BIRN’s pattern shop