Designing and consulting in the field of technical elastomeric products: rubber, rubber-metal or polyurethane is an integral part of the activity and comprehensiveness of the services offered. Active participation in the early stages of product design is necessary in terms of:
- selection of appropriate construction materials that can be used in the conditions of application of the product described by the customer,
- analysis of the technological aspects of the structure and verification of the customer's specifications and requirements in relation to the production process, as well as advice on possible changes aimed at reducing the cost of implementation,
- design and execution of production instrumentation of the product,
- conducting trial production and prototyping of the product along with tests and measurements using the advanced 3D scanning technique using optical measurement scanners,
- designing the serial production process on the basis of the prototypes made, together with the development and submission of PPAP documentation in accordance with the APQP methodology and the requirements of IATF16949:2016
In the case of polyurethane products, we select the right materials for the product application and verify customer's specifications and requirements on the basis of our extensive experience and in cooperation with leading research and development centres both in Poland and abroad.
In the case of moulded rubber and rubber-metal products, the design of the product manufacturing process is based on the use of an innovative Virtual Moulding computer simulation method based on the finite element method (FEM). This process consists primarily in replacing the physical attempts to inject the rubber mixture with virtual tests, even before the mould is physically made.
Virtual Moulding is a new and unique technological solution in the injection moulding industry, created to analyse and optimise processes, moulds and details to increase quality, productivity and productivity. Thanks to the rheological and thermal balancing of the entire system, considering all its elements (hot runner, cold runner, tempering, mould inserts, etc.), the following are obtained:
- short preparation time for the production process,
- saving production break times,
- guaranteed stable injection process,
- stable production quality assurance,
- controlled influence of process parameters on the quality and characteristics of workpieces,
- recording the evidence of tool iteration.
Compared to conventional injection simulation software, Virtual Moulding enables a much better understanding of the causal relationship in terms of detail quality, tool, system energy efficiency and “technology window”. The integrated method of analysis of the moulding and all process elements, such as the tool structure, hot channels and control parameters significantly increases the predictive accuracy of the simulation.
The software allows you to analyse the following aspects of the process:
- rubber injection simulation (filling) or thermal analysis in cycles only,
- avoiding rubber degradation – analysis of the degree of vulcanisation,
- monitoring Scorch values during injection,
- selecting cycle parameters,
- calculation of injection pressure and mould clamp for machine selection,
- optimizing the location of gates or runners, e.g. to reduce pressure or injection time,•
- election of mould heating power, insulation thickness and heating time and cycles to heat the mould evenly,
- weld lines,
- detection of air traps.