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.
Solution® 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 eleven easy but fundamental steps:
1
Planning
At the start of each project, all production process phases are analyzed, optimizing the timing in order to guarantee the highest quality while respecting the deadlines.
2
Product design
Solution® provides complete support for the development of new products or the improvement of existing products, from the choice of the right polymer to the final design, through a meticulous and functional industrialization process, optimizing assembly interactions and behavior in various environmental and operating conditions, with particular attention to production efficiency.
3
FEM Analysis
We perform static and dynamic, linear and nonlinear FEM analysis, simulating the behaviour in various thermal conditions and with different stress types. We pay particular attention to the topological analysis, necessary for product optimization, strengthening it in critical areas and removing unnecessary material where it is not needed. The interpolation of these activities generates a large part of the added value of the product and its competitiveness.
4
Moldflow
Simulations of fill flows and deformations on the part (shrinkage, warpage) are an important investment by means of which the ideal profile of the injection system and its ability to transfer material from the injection machine to the cavity in the most efficient way possible is studied, respecting the intrinsic characteristics of the plastic material and the correct processing process. We verify that the filling of the part is balanced, without cold joints and air traps, with acceptable filling pressures and packing, that the arrangement of any fibers is in line with the anisotropy of the material, ensuring that the deformations are compatible with the geometrical tolerances of the product, guaranteeing suitable and repeatable molding conditions.
5
Mold Design
In the mold design phase, Solution® strictly follows the classic method that starts from a 2d setup study on which the mold guidelines are sketched, and then proceeds to the complete development of the 3D project. By exploiting the multisector experience and the specific design technique of Solution®, we generate that fundamental added value that characterizes an excellent mould, which must be efficient, reliable and essential.
7
Production
In the 4000sqm at its disposal, Solution® uses CNC machining centers with 3, 5 and 9 axes continuously and drilling machines of last generation. The two cranes, which cover the entire working area, can handle semi-finished products and complete moulds up to 20 tons, machining centers can mill plates up to 2000x2200mm. Among the more than 100 tools available to the operator, all machines are equipped with two probes for measuring critical dimensions of machined parts directly in the machine.
9
Trial
Solution® has four BMB KW hydraulic machine of 100, 270, 350, 800 tons. During trial, the mold is tested and parameterized in compliance with geometric tolerances and cycle time objectives. Once optimal and sustainable parameters have been achieved, the mold is tested for 24/48 hours to verify its mechanical reliability. The trial machines positioned next to the assembly department make it possible to carry out any adjustments in extremely short time.
6
Cam
Once the 3d design has been approved, each individual component of the mould is sent to the CAM office for the toolpaths programming, necessary for the construction of the parts through milling cycles, electro-erosion and drilling. The processes are mainly performed on CNC milling machines with 3, 5, and 9 continuous cartesian axes.
8
Fitting/Assembling
This is the phase where the value added of the production process is generated. The careful design and manufacture of components to the highest degree of precision would not be sufficient to guarantee the reliability and mechanical fluidity of machines without a scrupulous assembly and flexible adjustment, modulated on the real operating conditions. The production performance of the mould is analysed and improved, by checking the quality of heat treatments, the fluidity of movements, the efficiency of the thermal conditioning circuits, the response of the injection systems, sensors, plumbing and all the control and management equipment. The craftsmanship quality is expressed in a positive combination of manual skills, mechanical sensitivity and technical and technological knowledge, aimed at producing a well-optimized mold, able to enhance the maximum production performance.
10
Quality control
In the Solution® mentality, quality is a value that must be expressed before and during the production phase, not a result to be measured at the end of the process. Naturally, the samples produced during the trials with the ideal parameters are measured, scanned and certified, in the logic of a quality carefully planned upstream and pursued equally meticulously throughout the production process.
11
Customer Service
Our customer service department provides support during the mold testing and start-up phase. We also guarantee service for the whole life of the mold.
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