Moulding design, building and test
- Product engineering and process analysis
- Simulation and material analysis
- Prototyping and tests
- Mould making
- Trial
- Quality control – metrological analysis
- Consulting and formation
- Customer service
Where there is an obstacle, Solution ® sees a challenge for the innovation.
Every product can be enhanced, every process can be integrated, every mould can be made more reliable and compact.
Our method
Study and analysis
Solution invests part of the preliminary time, in the beginning of every project, on the study and analysis of the plastic part that will be produced by injection moulding. This strategic moment, intended to predict any kind of issue after the building of the tool, is organized in twelve easy but fundamental steps:
1
Planning
Feasibility analysis and planning of the actions.
2
Product analysis
Evaluation of the criticality, verification of the tolerances, thicknesses, shapes, coupling, undercuts.
3
Simulation
Structural analysis of the mould, deformations and simulation (fill, pack, cool, warpage) by moldflow (powered by Cadmould Analysis software).
4
Technical specifications
Examination of the customer’s specification and integration of it in the Solution’s standard technical document.
5
Design
In this phase, probably the thorniest one of the entire process, the designer proceeds with the 2D planning of the mould and progressively goes on with the development of the 3D project, by using the CAD software (powered by Top Solid 6, Top Solid 7 and Catia softwares).
7
Production
On a surface of 4000sqm, Solution uses 3, 5 and 9 axis CNC milling machines and drilling machines of last generation. The two cranes, covering all the working area, are able to move semi finished products or entire moulds up to 20 tons, the machines can mill plates up to 2000x2200mm.
9
Trial
For the internal trials of the moulds, Solution is equipped with five BMB injections machines of 100 – 270 – 350 – 600 – 800 tons. During the testing phase we can satisfy the need for small preliminary productions. The testing of the molds is carried out by qualified personnel with the aim of optimizing the production process, trying to achieve the best possible cycle time while maintaining all the geometric, aesthetic and functional qualities of the piece. In the final stage of testing, we bring the mold to work in extreme conditions to test its real reliability, highlighting potential latent criticalities. The strategic position of the injection machines fleet, just a few meters from the adjustment department, allows all adjustments and any modifications to be made to the molds to be carried out in an extremely short time.
6
Cam
Once finished and in according to the customer, the projects are sent to the CAM office for the setting up of the milling machines (powered by Hipermill software).
Solution can entrust on CNC milling machines with 3 – 5 – 9 axies.
Solution can entrust on CNC milling machines with 3 – 5 – 9 axies.
8
Assembly/Adjustment
In this phase, the decisive added value of the production process is generated. The care in the design and construction of the components to the highest degree of precision would not be sufficient to guarantee the reliability and mechanical fluidity of the machines without scrupulous assembly and flexible adjustment, modulated on the real operating conditions. The production performance of the mold is analyzed and improved, verifying the quality of the heat treatments, the fluidity of the movements, the efficiency of the thermal conditioning circuits, the response of the injection systems, of the sensors, of the hydraulic systems and of all the management and control. The quality of the craftsmanship is expressed in a positive combination of dexterity, mechanical sensitivity and technical and technological knowledge, aimed at producing a well-optimized mould, capable of producing maximum performances.
10
Quality control
In the Solution mentality, quality is a value that must be expressed before and during the production phase, and not a result to be measured at the end of the process. Certainly the samples produced in the tests with the ideal parameters are measured, scanned and certified, in the logic of a quality planned scrupulously upstream and equally meticulously pursued throughout the production process
11
Assistance
Thanks to its two mobile workshops, Solution Italy guarantees prompt on-site assistance for maintenance, testing and non-invasive repairs.
Solution Italy S.r.l.
Via Braccolino snc
60030 Belvedere Ostrense (AN)
ITALIA
P.IVA - C.F. 02407830427
Solution is certified ISO 9001 since 2018
© Copyright 2021 Solution Italy
credits: mpm comunicazione