(l-r) Don Hendrickson, Executive Director of OMIC R&D; Dr. Mostafa Saber, Professor and Deans Fellow of Oregon Tech; Johannes Zuckschwerdt, CEO of GEFERTEC GmbH; Devyn Duryea, Research Associate at OMIC R&D; and Kyle McGann, Additive Machine Solutions Researcher at OMIC R&D
Dr. Mostafa Saber with an injection mold created on the GEFERTEC ARC605, believed to be the largest injection mold ever created through additive technology.
The Oregon Manufacturing Innovation Center Research & Development (OMIC R&D) recently hosted Johannes Zuckschwerdt, CEO of GEFERTEC GmbH, for a visit to its Scappoose, OR, facility. The trip was more than a courtesy call-it was a celebration of a partnership that has been generating tangible results for Oregon's manufacturing community since GEFERTEC joined the OMIC collaboration in 2021.
GEFERTEC, a Berlin-based pioneer in wire-based additive manufacturing (AM), provides OMIC R&D with a Wire Arc Additive Manufacturing (WAAM) system that operates on the center's production floor. The GEFERTEC 3DMP arc605 Wire Feed ADDMFG System is a $1.1M capital investment leveraging State of Oregon bond funds with a hefty discount by GEFERTEC as part of their membership contribution. Unlike traditional subtractive manufacturing that removes material from a solid block, WAAM builds large metal components layer by layer using a welding wire feedstock, offering significant advantages in speed, material efficiency, and design flexibility. Over the past four years, that machine has been put to work on a growing portfolio of applied research projects in partnership with OMIC member companies.
Among the most notable projects to emerge from the GEFERTEC collaboration is a large-scale injection mold produced in partnership with OMIC member companies and led by Dr. Mostafa Saber of Oregon Institute of Technology and OMIC R&D. The mold is believed to be among the largest, if not the largest, injection molds ever produced through AM, a milestone that speaks to both the capability of the GEFERTEC system and the applied research ambition that defines OMIC R&D's work.
A spokesperson noted: "Injection molds are notoriously difficult and expensive to produce through conventional methods, often requiring weeks of precision machining. Producing one of this scale additively demonstrates a potential path toward faster, more cost-effective tooling-an outcome with significant implications for manufacturers across industries."
Dr. Saber said: "This project pushed the boundaries of what AM can realistically achieve at scale. The ability to produce a mold of this size using the GEFERTEC WAAM system, in collaboration with OMIC member companies right here in Oregon, is a meaningful proof point for the technology. It opens doors for manufacturers who have historically been priced out of large-format tooling, and that is exactly the kind of impact applied research should have."
During his visit, Zuckschwerdt toured the facility, engaged with OMIC R&D's research team, and discussed opportunities to deepen the collaboration as WAAM technology continues to evolve. For Zuckschwerdt, the visit offered a firsthand look at how GEFERTEC's equipment is being applied in a real-world research and industry context.
"Visiting OMIC R&D was a truly inspiring experience," said Zuckschwerdt. "The team here has a genuine passion for innovation and a hands-on approach to manufacturing that perfectly complements what GEFERTEC is working to achieve. Seeing our technology being used to accomplish something like this injection mold, and knowing it is directly benefiting Oregon manufacturers, reinforces exactly why partnerships like this one matter."
Executive Director Don Hendrickson emphasized the importance of long-term industry relationships in fulfilling OMIC R&D's broader mission: "Having Johannes here in person was a great reminder of what makes this work so exciting. GEFERTEC has been a fantastic partner since day one. They not only provide world-class equipment, but help us build a culture of innovation at OMIC R&D. The injection mold project is a perfect example of what is possible when great technology meets a committed research team and engaged industry partners. We look forward to continuing that work together for years to come."
For more information contact:
Jon Elias
Director of Marketing and Communications
OMIC R&D
33701 Charles T. Parker Way
Scappoose, OR 97056
503-821-1155
jon.elias@oit.edu
www.omic.us
GEFERTEC GmbH
info@gefertec.de
www.gefertec.de