DESIGN

Engineering
Co-design
Reverse Engineering
Prototyping
Filling simulations
Deformations
3D Design

Starting from a geometric model, a drawing, a sample or simply from customers’ ideas or needs, we develop technical solutions for one- or multiple-cavity moulds, injection moulds with hot runners, single-or multiple nozzle, with automatic thread unscrewing; as well as with mould for co-pressing (steel-plastic, plastic-plastic, plastic-plastic-rubber with manual or automatic loading)

We always perform FEASIBILITY STUDIES to analyse the several technical solutions for each part, taking into consideration shrinkage and deformations of raw material, as well as production needs and all further aspects aimed at optimising the pressing process.

We understand design as a process to develop in close contact with the customer. We provide support in CO-DESIGN to find the best technical solutions and reach high performing tools concepts.

Our Software

CAD
SIEMENS NX
PRO-ENGINEERING WF 4
VISICAD R 21
CATIA V5

CAM
WORKNC R 22
TEBIS V4

CAE
MOLDFLOW
MOLDCOOLING
WARPAGE

We run FILLING SIMULATIONS aided by the software MOLDFLOW. This service allows us to simulate the behaviour of plastic during the whole process, identifying the areas more suitable for stress material.
We associate to this analysis also the MOLDCOOLING and WARPAGE to get feedback on temperatures distribution inside cavities, forecasting deformations on the part after moulding process.

Obtained results are shared with the customers, together with our process analysis and out proposals for optimizations.

For some projects we perform REVERSE ENGINEERING following an inverse design route, which starts from a physical existing model and gets back to the geometric model of the part. Besides the traditional contact feeler-pins / tracer points we use laser scanning systems thus guaranteeing precision on the order of a few hundredths.

Working method

Design / Manufacture Planning

Preliminary layout
for customer approval

Steel purchase
and design completion

Manufacture and
activities monitoring

MANUFACTURE

CAM
Milling
Drilling
High precision erosion
Assembly
Adjusting
Polishing

Our continuous investment in the latest equipment and processes, our high quality focus and our steadily enlarged range of services make us a long term reliable partner. We manufacture tools with high level difficulty, internal undercuts, thin thicknesses, applying the most advanced technologies:

Light guides        Chromes parts
Heat&Cool        Rotative moulds
2K Material        Gas injection
Insert molding

After machining, all manufactured components are scanned and controlled through the program Faro Arm  . This mobile device allows us to check machining’ s quality and reduce the assembly timings.

We purchase the raw material from accredited suppliers such as Böhler, Uddeholm; for hot runners we rely on certified companies, which precisely recreate injection channels, guided by the results of our analysis and following their long-standing experience.

Plastic injection Mould

Instrument panel

Faro Arm

plastic injection Mould

Door

Our machinery

CNC 5 AXES

1 DEKEL MAHO DMU125 P
1 HERMLE C-50
1 HERMLE C-40
1 SPINNER U620
1 DIAMOND PARPAS
1 SACHMAN TRT 314 HS
1 OMV PERLA

CNC 3 AXES

1 DECKELMAHO DMC 100V
1 DECKEL MAHO DMC 63V
 1 SPINNER VC750HS

EDM

WIRE EROSION ONA AF35
1 WIRE EROSION ONA NX6
1 SPARK EROSION ONA DATIC F60
MICRO DRILLING

LATHES/DRILLING

1 IMSA MF1250/2FL
1 LATHE SPINNER TC600MC-657

SPOTTING

1 UTAS 800

We have a dedicated department completely dedicated to FINE AND OPTICAL MILLING : the use of advanced software combined with technologically advanced machinery inventory allows us to get high quality work.

Generally we produce a sample for the customer where we simulate the working conditions.
In this way we can offer the customer a preview of the final result of the process and simultaneously adopt measures to increase the quality of finishing

Thanks to deep study of machine parameters in relation to the types of steel and following a number of tests carried out in collaboration with suppliers of tools, we have gained extensive know-how in processing highly complex surfaces.

We are able to achieve the minimum of milling rays equal to 0.08mm and to perform optical surfaces of very low roughness !

TESTING

Sampling
Pre-serie
Parts production
2D/3D measurements

Our strenght lies in the full service approach which is customer’s advantage. Getting the result of the work done is essential : this is why we test the tools before shipment, to find out the best process parameters.

We can execute samplings on machines with closing force from 60 ton up to 1600 ton.

Plastic material used for injection are :

     PC          ABS+PC
PP              ABS
EPDM      PMMA
PA6          TPE
GLASS
FIBER

After the sampling we execute 2D/3D DIMENSIONAL CONTROL, which certifies the reproducibility of the part accordingly to the foreseen tolerances.

We use 3D Steinbichler Zeiss to scan cavities and casted parts through the software POLIWORKS inspector, Hexagon Metrology, Coord3 Metrology.

ASSISTANCE

Laser engravings
Laser welding
Maintenance
Modifications

We provide complete and long-lasting service : we are available to intervene in case of modifications and optimizations on the tools.

Our tooling department assists the customers also for MAINTENANCE activities. We make all operations ourselves, with our skilled team. If requested, we guarantee assistance also at our customers’ plants.

assistence-operator
3d-visualizer

Thanks to our internal organization of maintenance and assembly activities, we are able to manage modifications on the tools in very short time, aided by machines which are dedicated to this service. This allows us to give support to our customers after the shipment and in case of urgencies, not interrupting the production flow of the new tools.

Each assistance emplacement is equipped with a 3D VISUALIZER  that helps the operators during assembling, adjusting and maintenance, making the activities go precise and faster.