example industrialization
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Example of Industrialization Ingenuity/Innovation Where speed is critical for success
Engineering Services, Industrialization Aarau, May 2015
Y: Best cost efficient design for new products Business design engineers develop new products with plastic parts
to achieve functional and economic goals. Therefore, they need
technical support regarding the molding process, material
opportunities, and tooling aspects to get optimized solutions.
X: Industrialization support for plastic components For design recommendations for new developments, the
Industrialization Team uses software like Moldex3D and the online
quotation system from Proto Labs Ltd.
With these tools, Industrialization Engineers achieve an optimized
mold design with a greatly reduced molding process cycle time.
For the fast visualization we use outputs from Moldex3D and
injection design services provided by rapid prototype suppliers
during the offer phase.
Z: Shortest lead time for samples “Time to Market” is the key. Fast availability and economics are the
most important factors when producing prototypes.
Industrialization Team Aarau supports the Business Unit in getting
the offers and ordering prototype parts from rapid tooling vendors.
Three weeks after ordering, molded parts are delivered in the
required material. Additional parts, for example ones injected with
different material, are available within 10 days. This is an extremely
short lead time.
Rapid tooling In the rapid tooling method, a supplier molds plastic parts in a
milled aluminum tool with a custom 3D CAD model as input. Every
customer‐required thermoplastic material can be molded within 15
days. In case of design changes, Rockwell Automation can get new
components within the shortest possible time. Rapid tooling costs
for complicated parts, such as the example shown at right, are
approximately $12,000 including tooling and 50 sample pieces. A
steel tool for such a part usually takes three to four months to
create and the costs are much higher.
The plastic parts produced this way are made from the same
material as the final serial parts, and therefore they can be tested
under real operating conditions. The results obtained will deviate
very little from the serial parts and tools. The parts produced with
rapid tooling are limited to 50,000 pieces, but they can be used in
final assembly providing very good experience for high volume
production.