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Via Monfalcone 3
33100 Udine
Italy
Vat code: IT02944760301
pec 2psupport@pec.2psupport.com
Product & Process Design
This is an eighteen thermoformed parts plus four polyurethane parts project to transform a standard commercial vehicle into a pick up for the LCV (Light Commercial Vehicle) sector.
2023 SPE Thermoforming Conference
Part Competition Award Winner
Two of the most challenging parts of the project are the right and left rear corners, that integrate the original back lights. In the first, easier, original design version, the two parts were composed by multiple outer and inner parts with poor edge design. The final products are made by one outer and one inner shell each. The inner parts purpose is to reinforce the outer ones, to be the base to install the lights and the interface with the car body.
The Right and Left rear corners are formed in a two cavity articulated mold. The mould was designed in order to release the formed shell, without any marks into the part. To release the heavier undercut, 5 inches-130mm deep, and the many other opposite ones, the standard machine forming process was also modified.
With the strong risk analysis adopted, it was possible to move forward directly and successfully with the serial aluminum, billet and cast post machined, thermo-controlled molds.
Technical and Economic Analysis
This is an example of how the technical decisions affect the efficiency and the production costs.
Mold material Vs ROI
Production Layout Vs Productivity
Through an engineering approach the customer needs and its mold production process were deeply analysed. Several manufacturing methods and materials were compared and related to the parts’ production. The output of the project was a spreadsheet that allows the customer to keep decision based on numbers.
As in many other processes, the productivity of thermoforming is also affected by the layout. A precise analysis of all aspects of the process, such as times, materials and parts handling, line efficiency, batches, safety and many others including costs, is really important to properly allocate the human and economical resources.
Precise Investigation
Process set up and understanding is not only matter of experience.
Our senses could be not enough: that’s why we constantly use our portable infrared camera for thermal analysis.
