Process
Step 01
Tool & Part design
Product industrialization, we work together with the customer to create the best final result.
3D design during the different steps, we continue working side by side with the customer. Each mold is equipped with its own “Technical Book”, containing complete information about its application and the certificates regarding the material used and the treatments performed.
Software CAD CAM, Catia, Unigraphics NX, PTC, Cimatron
Co-design activities to realize components using HPDC.
Manufacturing of dies with advanced features:
- Vacuum
- Squeeze Pin
- Jet Cooling
- Conformal Cooling
Step 02
PROCESSES VIRTUALIZATION
FEM Analysis, Simulations, Tool Virtualization to predict its useful life.
Virtualization of the Die Casting Process (TPV).
We design tools with innovative features:
- Dosing system analysis
- Ejection force
- Tool heat treatment analysis
- Burst test study
Software
- Ansys
- Magma
- ProCast
Possibility to run FEM analysis combining predicted defects and residual stress generated by the die casting process.
Step 03
CNC MACHINING
High precision manufacturing with cutting technology using 5 axis machines.
Zero point clamping systems in every CNC machine. All technical parameters of the cutting tools are set by our CAM department.
5 milling machines with 5 axis
(max.stroke 3800×1200)
3 milling machines with 3 axis
(max.stroke 2100×770)
1 deep drilling machine
(max.stroke 800×800)
Step 04
Erosion
The customization of the EDM machines electronic parameters allows a shortening in terms of machining time and electrode wear while guaranteeing the quality of the treated surfaces.
3 spark erosion machines
1 wire erosion machine
Advanced co-design allows us to realize elements with complex profiles. In-house manufacturing of the electrodes.
Step 05
Assembly
5 assembly workstations are set according the Kaizen concepts to reduce MUDAs. We manufacture moldsup to 18 Ton.
Highly experienced operators in mold polishing and final assembling.
5 assembly workstations 1 grinding workstation.
Step 06
QUALITY CONTROLS
Photometric control of all active parts is carried out through best fitting activities at the end of each manufacturing step. This permits to shorten the assembly times.
3D controls, Best fitting
3D photometric control system GOM, accuracy 0,01
