PROTOTYPES

For our clients we produce prototype elements, pre-series and small serial productions for the following sectors: automotive, electrical appliances, and automation (special machinery intended for many different uses).

Having all the tools necessary within our company for the realisation of the final product (feasability analysis, design and fabrication of soft tools, hydraulic and mechanical presses, NC press brakes, 2D and 3D laser cutting and workcells for welding and spot welding) enables us to have very short execution times. 

These can vary roughly from two weeks for the simpler and smaller items to four weeks for items of larger dimensions and with more notable complexities.

A prototype is necessary as it represents the phase which preceeds the fabrication of the die for serial production. It allows us to evaluate the aspects and problems which we will then need to tackle when designing the final equipment. Instead the pre-series can help to cover the first few stages of the supply when some pieces are needed before the final equipment is ready.

FEASABILITY – Through the feasability analysis we define and verify the production cycle most suitable for the exact realisation of the item. SOFT TOOLS – Once the production cycle has been defined, the necessary forming equipment is designed. This equipment (commony referred to as “soft tools”) is generally “very essential” and “not very perfected”, because it needs to be inexpensive and made in a short amount of time. In any case, the level of fine-tuning for this equipment can vary according to the client’s requests, and also this light equipment, as for serial dies, can be made in line with specifications from the client.

During the production of prototypes and of small series productions we generally do not fabricate the equipment needed for drilling and trimming profiles, because these can be made with the use of 2D and 3D laser cutting. This enables us to be more flexible when introducing changes (i.e. adding, removing, moving drills and trims) and to further reduce investment costs.

Once the necessary equipment has been constructed, the components are pressed and trimmed during a sequence of manufacturing phases which often alternate between these two processes. 

To carry out the stamping operations we have presses available, which have a power of a minimum of 100 tons to a maximum of 630 tons. 

Should the tonnage not be available internally, we can carry out the stamping operations externally with a partner company not far from us which has presses with a power of up to 1200 tons and a surface area of 4×2 metres.

An example of a pressed item in aluminium before laser trimming.

The trimming operations can be carried out through the use of 3 and 5 axis laser machinery. We have two 3 axis laser cutting machines (4KW) for cutting flat semi-finished products and two 5 axis laser machines (4KW both CO2 and FIBRE) for 3D cutting of already constructed components which can be medium-large sized (4000 mm x 1200 mm).

The constructed components undergo inspections during the entire production cycle and are delivered to the client together with dimensional reports and quality certifications.

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