Moulds and dies
As a result of the type of projects we usually take part in, we have been obtaining for years the knowledge and tools needed to successfully undertake the research and development of techniques to design and manufacture moulds for different metal, thermoplastic and thermoset transformation processes.
In each case, the design of moulds and dies is done based on the corresponding process simulations according to the chosen process: casting, shaping, injection, in-mould decoration, etc.
The use of modules and inserts in versatile moulds makes it possible to evaluate different design solutions and alternatives, whereby we can give our clients a faster and lower-cost response.
These moulds are particularly useful for presenting concepts and proving the validity of a proposal for a design, a process or both. These technological demonstrators provide the basis on which to begin to analyse their technical feasibility before making the investments needed to reach production.
Simulation allows to select the design variables of a mould such as its location, the number and type of inputs, the feed system and the cooling system, and their efficiency. In the case of processes for moulding metal alloys, cast iron, light alloys, and so on, both the design of the moulds (geometry of feed channels, sprues, etc.) and the tools therefor can be highly optimised by using foundry-specific simulation programmes.
Simulation becomes ever more essential as the complexity of the process increases, and must be always properly supported by both experience and the testing of the machines in order for it to be validated, starting from, of course, the rheological, thermal and mechanical characterisation of the materials.
We perform an exhaustive validation of this type of programmes, something which, together with the development and implementation of our own predictive models – mechanical properties, microstructure, porosity, leads us to predict the mechanical and microstructural properties of the parts. Finally, these properties can be validated by using instrumented moulds and material characterisation techniques.