Initial Situation

Large products fabricated in small series (less than a few thousand) are usually produced in metallic materials, using traditional techniques. At present there is considerable pressure to use polymeric and composite materials, as these allow weight reduction, ergonomic and aesthetic improvement, increased surface complexity and multi-function incorporation within final parts and final products. The principal constraint which has been limiting the use of polymeric and composite materials in this type of products, is the excessive cost of the mould, which is reflected in the cost of parts.

A tollbooth machine cover is used as a demo-part in this Case Study. The covers and frames of tollbooth machines are produced from sheet metal in series of some hundred parts. As it is difficult to spread tooling-related costs over a small batch production, conventional manufacturing methods and technologies are currently used. These entail strict design and aesthetic limitations, reduced dimensional precision and problems regarding the feasibilitiy of using efficient assembly and dismantling processes without creating vulnerability to acts of vandalism.

Objectives





The objective of this Case Study is to develop the concept of moulds and dies for high variety/small production runs, considering innovative tools, concepts, architectures, design and production methods, using materials and technologies adapted to the requirements of cost-efficiency within the context of a short life-cycle.

The tollbooth machine cover will act as a demo-part integrating the most important product concepts, technologies and know-how, which caneasily be transferred to other industrial sectors, in order to meet the specific market requirements.

Solutions

Part and tool design solutions achieved using knowledge based design systems

Development of modular mould concepts and manufacturing solutions, compatible with small batch/high variety requirements, cost restrictions and tool life cycle

Development of both generative and advanced machining processes in a drive to shift towards increased flexibility and cost-efficient mould production

Development and evaluation of Mobile Engineering solutions and extended services consistent with tool life cycle, creating new roles for mould-makers, as active product development partners and providers of value- adding services