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INJECTION MOULD

October 2015

Company Profile

company profile – October 2015 INJECTION MOULD

ESISTAMPI MISSION Esistampi is one of the main Italian companies for design and manufacture of injection moulds . Since 15 years Esistampi cooperates with large Italian and European industrial Groups in different fields (automotive, motorbikes, trucks, technical parts, containers), to allow them to deliver on time good quality parts.


ESISTAMPI MILESTONES The reason of Esistampi’s growth, while the mouldmaking industry is generally in troubles, comes from the combination of experiences gained by the shareholders during their professional carrier.

THE GROWTH In 5 years Co. Esistampi triples his employees and quadruples the turnover.

2008-13

THE INDUSTRY Co. Esistampi aquires co. Ses to consolidate its grow and expand into new markets and sector.

2014

THE CHALLENGE He takes the challenge and begins to work on his own.

1987 THE CRAFTSMANSHIP Luciano Volpini begins his carrier as workman at Ses.

1972 THE FIRM He establishes Co. Esistampi together with his partners Roberto Lucaboni and Luca Piccioni.

2001

2014 - SES: a skilled workshop dedicated to large tools is bought by Esistampi

AUTOMOTIVE Product and process

industrialisation WASTE BINS

Thin walls and fast cycles

INDUSTRIAL CONTAINERS

Up to 8000T of clamping force

WASTE BINS From 500L up to 3200L

FURTHER IMPROVEMENT OF CAPABILITIES, KNOW-HOW AND EFFICIENCY

The goal of the adcquisition of the SES workshop and skilled employees is the combination of

specialistic know-how in large moulds with the competitive business model of Esistampi, merged

into a larger and more efficient building.

SLIM STRUCTURE DINAMISM

FLEXIBILITY PROACTIVITY


SERVICES Thanks to this new organisational model, Esistampi can supports its customers, with an high added value, for the whole development process of the project, assuming the technical / economic responsability according to the turnkey approach:

ENGINEERING SIMULATION DFM MOULD DESIGN MOULD MANUFACTURING TRIAL AND TUNING SOP AT CUSTOMER PREMISES


The production capability of our Company allows to approach with granted result the most complex needs, both from a technological and manufacturing point of view (as, for example,

multiple tooling projects to be delivered in short leadtime)

CAPABILITY

Some data people Production capacity Main SWs or machinery

Tech Dept // 9 20.000 h/y Catia, Delcam

CAM // 5 8.000 h/y Delcam

MACHINING // 33 100.000 h/y 14 cnc; 2 drilling, 4 erosion

FITTING // 20 38.000 h/y

CRANE // n° 10 Up to 60 T

TRIAL // 3 Triulzi 3000t / NB 1300t / NB 650t (80% of moulds can be tested in-house)


WE KEEP YOUR PROMISES End market needs are every day more challenging: • Reduced leadtime to be granted • Optimisation of investment for faster

payback • High quality • Flexibility to manage modification during

the mould manufacture Esistampi is the right partners to accept such challenges without risks.


REFERENCES AND CASE-HISTORY


REFERENCES: ENVIRONMENT AND MATERIALS HANDLING


BIG BOXES AND PALLETS

CUSTOMERS

PRODUCTS

Craemer Helesi Macroplastics Schoeller Allibert (Linpac) Otto Viscount Multitank Wenco Al Sharq Rehau Femsa

Pallet Industrial containers Pallet Boxes Agricultural containers Folding containers Special containers


Product design and development

FEM structural analysis for optimal weight/performance ratio

Assembly analysis

Industrialisation


PRODUCT ENGINEERING

Warpage Analysis

Definition of optimal injection system

Definition of optimal cooling lines path

Use of special materials and inserted ineserts

PROCESS ENGINEERING



MULTI VERSION MOULDS

STACK MOULDS

MULTICAVITY MOULDS

MULTIPLE TOOLING PROJECTS

MOULD CONFIGURATION


Case history FOLDING IBC CONTAINER | LINPAC 1 cavity tool for Base 1000 x 1200 x 356

1+1 cavities tool (sandwich) for Short Walls 1000 x 1200

1+1 cavities tool (sandwich) for Long Walls 1000 x 1200

1+1 cavity injection tool for Door for Long walls 800 x 1200

2+1 cavities injection tool for Skids for IBC Container 800 x 1200

Base clamping force: 3000T; cycle time: 150˝

Walls clamping force: 1200-1500T; cycle time: 50˝


Case history BIG BOX 800/1000/1200 X 625/760 | HELESI BIG BOX 1100/1200 X 630/760/850 | HELESI


Case history MACRO BIN 48 | 2004 It is the biggest monobloc bin ever realized. External dimensions are: 1.222,4 mm (L) x 1.222,4 mm (W) x 1.333,5 mm (H), tare of 81,6 kg (+/- 5%), molded with an horizontal 8000T injection machine.

Even though the constructive, dimensional and structural complexity, the tool entered production after only one trial.

TOOL WEIGHT 110T 8000t

CLAMPING FORCE


Case history PALLET | 2008 Very high perfomance pallet, both for its load and its impact. Realized in two parts (top and bottom) welded.

The high performances are matched with its competitive weight thanks to a focused use of expanding agents.

BOTTOM TIME CYCLE

49’’ -10% WEIGHT REDUCTION FOR EXPANDED


Case history THIN WALLS BINS | 2009 The great experience reached by Co. Ses in the manufacturing of waste bins, has allowed to find technical solutions relative to the injection system and the pressures distribution able to reduce at the minimum both the article weight and the time cycle.

BIN WEIGHT 360L

10.4KG 41SEC BIN TIME CYCLE 240L


Case history WASTE BIN | 2007 It’s one of the biggest monobloc injection waste bins ever realized.

The product has been industrialized to optimize both the structural and functional performances of the product, and the productivity and reliability of the tool.

WASTE BIN CAPACITY

3200l 185T TOLL WEIGHT


Schaefer

Linpac

Femsa

Al-Sharq Factories

Palec Ecologico

Sacmi

Perstorp

Allibert

Otto

Nilkamal

MATERIALS HANDLING

CUSTOMERS

Stack-Nest containers

Folding containers

Bottle crates

Industrial containers

Agricoltural containers

PRODUCTS


FEM structural analysis for optimal weight/performance ratio

Assembly analysis

Industrialisation

MATERIALS HANDLING

PRODUCT ENGINEERING

Warpage Analysis

Definition of optimal injection system

Definition of optimal cooling lines path

Use of special materials and inserted ineserts

PROCESS ENGINEERING


MATERIALS HANDLING

STACK MOULDS

MULTICAVITY MOULDS

MULTIPLE TOOLING PROJECTS

MOULD CONFIGURATION


HOUSEWARES AND PAILS BOXES

SHELFS SHOES CONTAINERS

PAILS

Industrial – Food - Housewares


REFERENCES - AUTOMOTIVE


AUTOMOTIVE exterior /

Grills spoiler

Mudguard Mudguard 2k

Pillarse Pillars 2k

interior / Consoles Pillars Ducts Carter Carter 2k

Under the hood/ Filter Box Ducts Ducts 2k Covers Tanks


MOTORBYKES AND INDUSTRIAL VEHICLES Moto

Handles Windows grills

Filter box Box luggage

Manifold

Industrial Vehicles/ Trucks Consoles Ducts Grills Mudguards

Scooter/ Shields Footboard Filter box Seats assembly


CASE HISTORY SECTOR // automotive CUSTOMER // MODEL // Volvo S60, CX60, V70 PRODUCT // Grill parts

Bi-material mould Cube technology Injection Abs+PC and Injection Pmma


CASE HISTORY SECTOR // automotive CUSTOMER // MODEL // New Lancia Y PRODUCT // cabin air filter and conditioning box

Assembled part dimension: 522x560x410 mm Material: PP-TD20 Mould dimension: 1240x2450x1150 mm Mould weight: 21.800 Kg


CASE HISTORY SECTOR // automotive CUSTOMER // MODEL // Porsche PRODUCT // Venting duct

Mould dimension: 1000x620x610 mm Mould weight: 3000 kg Material: PP + T20


CASE HISTORY SECTOR // automotive CUSTOMER // MODEL // Fiat PRODUCT // Grill Frame


CASE HISTORY SECTOR // automotive CUSTOMER // MODEL // Mercedes PRODUCT // Wheel arch shield

Mould dimension: 768x1078x765 Mould weight: 5.000 Kg Material: LDPE


CASE HISTORY SECTOR // automotive CLIENTE // PRIMA MODEL // Alfa Romeo Giulia PRODUCT // grill

Grill QV Chromed decoration Logo Housing


CASE HISTORY SECTOR // automotive CUSTOMER // MODEL // Alfa Romeo PRODUCT // Front window grill

PP TD30 + EMP60


CASE HISTORY SECTOR // automotive CUSTOMER // MODEL // Fiat PRODUCT // griglia

Mould Dimension: 1.400x646x724 mm Mould weight: 4.800 kg


CASE HISTORY SECTOR // automotive CUSTOMER // MODEL // PRODUCT // seat cover

Mould Dimensions: 650x1070x890 mm Mould Weight: 1200 kg


CASE HISTORY SECTOR // automotive CUSTOMER // MODEL // PRODUCT // front grill

Mould Dimension: 1.530x760x801 mm Mould weight: 5.800 kg


CASE HISTORY SECTOR // scooter CUSTOMER // Plasgomma MODEL// Honda SH 150 PRODUCT // Filter Box


CASE HISTORY SECTOR // moto CUSTOMER // Plasgomma MODEL // Ducati Multistrada PRODUCT // Rear handle assembly


CASE HISTORY SECTOR // moto CUSTOMER // Plasgomma MODEL // Ducati PRODUCT // Filter Box


THANK YOU www.esistampi.it

injection mould company profile - intercoex global · fem structural analysis for optimal...

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