SERVICES AND RESOURCES
Our designers have a wide knowledge in all cutting-edge design systems, such as Catia, Unigraphics or Creo (Pro-Engineer), as well as in I-DEAS, Solidworks, AutoCAD…. always adapting to our customers’ preferences, we are equally able to perform complete simulations in Magma and ProCAST.
Besides, the engineering department has a thorough experience in the practicalities of tooling conception and knows first-hand the needs of a foundry. Throughout the whole design phase, we keep a proactive attitude with our customers and the improvement proposals abound: in fact, the value creation on this early stage is crucial to achieve a satisfactory overall result.
We are also aware of the great importance that our customers give to confidentiality and secure data transmission and therefore, we make extensive use of the different available platforms and protocols (ftp, dcx, gcx, odette, c3p, oem, kvs…).
In the centre of the manufacturing process, our CAM department optimises machine resources, mainly through Powermill programming.
Every year, new investments in machining centres try to answer the new challenges posed by our clients, targeting simultaneously higher precision and bigger size allowance.
EDM and Other manufacturing resources
As an essential complementary activity to milling, Spark erosion makes the creation of complex shapes possible, as for instance when dealing with deep ribs. Hence we have one wire erosion and four deep erosion machines at our disposal.
One of these machines is additionally deployed as a key element within the fitting process for core boxes.
Our facilities are well-equipped to guarantee a proper and safe transportand handling of big volume and weight parts, for example, with 10 T, 20 T and 25 T cranes. y deployed as a key element within the fitting process for core boxes.
Deep drilling is undertaken as an internal operation, due to the fact that any lack of accuracy can put at risk the validity of the whole part. Lengths can easily reach 1600 mm in the case of complex cooling systems for structural parts’ dies.
Our welding area is well-equipped with preheating furnace, which allows us to perform with accuracy and safety many of the modifications requested by the customer, covering different techniques such as TIG, MIG or plasma welding.
Fitting and Assembly
In order to excel in casting, every skill must be detail-oriented. A careful fitting and mounting of the tooling is essential to bring the required accuracy to the closure and adjustment of the individual parts. To a large extent, this is still very much a manual job, in which one must strive with the endeavour of a master craftsman.
Our teams of fitters are specialized by type of product and all of them ensure the necessary experience to address the most challenging aspects of each project.
Our fitting press was designed and crafted internally and reaches a pressure of 200 bar and can handle up to 20 Ton per side to guarantee the complete closure of the dies and core boxes.
The best manufacturing is the one that achieves to replicate exactly what has been foreseen in the 3D model. By means of the high-precision photometry, the real part is compared with the one designed and points out any type of deviation between the two. The software confirms if all surfaces are within tolerance and presents these results in a very intuitive way, which is clearly helpful for our customers, while performing the validation of the tooling. The control reports are then submitted together with the final product and serve as a very useful reference during the whole live cycle of the tooling.
We also have at our disposal a Coordinate Measuring Machine, which is most convenient for a variety of tasks, such as for example, the measurement of deep inaccessible areas.
A true foundry on small scale, where core boxes of any type (cold, hot, vertical, horizontal…) can be shot, and where cast benches for gravity, tilting gravity, low pressure, high pressure … ensure first and foremost a high degree of flexibility to undertake trials on the various fields of castings.
Processes are monitored through the necessary equipment to maintain the cycle parameters as close as possible to those on the production lines of our customers. The resulting cast parts are then dimensionally controlled so that by the time the tooling exits our premises, the fine-tuning is completed and the product is deliver in optimal conditions.