A Groupe Gorgé Company

Transcript

A GROUPE GORGÉ COMPANY INITIAL provide a complete service that enables 360° product management, from development (Engineering, 3D Scanning / Inspection Report), to prototyping and even industrialization. Since 1991, INITIAL has been offering Rapid Prototyping, 3D printing and Additive Manufacturing services. In 2014, INITIAL acquired a second production site close to our headquarters that is dedicated to injection moulding in Chavanod, France. Complete Package Complete Package INITIAL is located in Seynod and Chavanod in the French Alps. INITIAL has been part of Prodways since April 2015 which is a subsidiary of the Groupe Gorgé. On an international level, INITIAL is represented in Spain and in Germany. Our confidentiality, reliability, quality and responsiveness make us the ideal partner. Mock-up 3D Scanning CAD rendering Moulds Today, making quality products in the shortest time possible is a top priority. From the design to the marketing of a product, you usually have to call on a range of professions and talk to lots of different people and this can lead to a loss of time and information. To reduce this inconvenience to a minimum, Initial offers you a complete service for the development and industrialisation of your product: • a consolidation of the various areas of activity on a single site, Our Service Bureau comprises: • an experienced Design Office, • a Digitising Centre at the forefront of technology, • a high capacity 3D Printing workshop, • an integrated Tooling and Injection section, • a streamlined organisation for a Complete Package and Rapid Manufacturing • a Metals division for new applications. We are true professionals in our field and are active in various business sectors such as: • aeronautics, • cosmetics, • medical, • sports and leisure, • automotive, • electronic goods, • domestic appliances, • clock making, etc Eager to provide you with the best service, we are doing all we can to continue to develop this Centre of Expertise, an indispensable resource for your company. • a concentration of skills, Contents • complementary trades, • a simplified approach through the effective coordination of all the parties involved, Complete Package 3 • a single contact point, • information in one place and kept confidential, Product Design & Engineering 4 • monitoring at each stage. 3D Scanning & Inspection 6 By entrusting your projects to us in their entirety, you benefit from all the advantages that our Development and Production Centre can offer. Rapid Prototyping 3D Printing 8 Rapid Manufacturing 17 Metal Additive Layer Manufacturing 18 Tooling Injection Moulding 22 Tractor cab The Complete Package, a new and highly effective approach. 2 3 Product Design & Engineering Product Design & Engineering Calculations and Kinematics Our design office, with its twenty plus specialists in industrial and consumer products, is at the core of our development centre. Exploded view Take advantage of our additional ability to manage your deadlines and so gain flexibility. Thanks to our high level of expertise, you can entrust your projects to us in complete confidence. We can start from an idea, a sketch, a specification or a designer’s mock-up. We take care of: Creation and Design • the entire development of your study in relation to your production resources. • the 3D modelling of your project using powerful software, • the production of the detailed drawings necessary for manufacturing or starting work on your production tooling Based on an evaluation of your needs as set out in the specification, we offer solutions taking account of aesthetic, cost, marketing and technical constraints. Raclette grill Our creation and design team provides a quality service and advises you on the choice of materials to use, as well as the technologies most suited to your projects. Calculations and Kinematics Using Pro/Mechanica, we make digital simulations of your product, in order to validate its design. To determine the distortion and different breaking points which could occur in use, we apply virtual stresses in the calculation software through finite elements. What you are looking for • The development of a new product or a new range • Improvements to an existing product • Research into innovative solutions From the calculations made, our design team is able to advise you on: • the dimensions of the part • its optimum geometry, What we offer • the choice of material, • various fixings. • Help with producing a specification • An in-depth knowledge of creative techniques • The development of an ideas file • Taking industrial property constraints into consideration Electrical circuit breaker Software • Pro / Engineer • CATIA V4 / V5 • Solid Edge 4 Multimeter Ultrasound monitor Benefit from our team’s breadth of skills, honed with the experience gained from a large number of development projects across a wide range of product areas. The solutions proposed will be applicable to your product’s context and environment, in order to make it as competitive as possible. Visualisation of stresses Rainwater collector 5 3D Scanning Checking 3D Scanning - Inspection Inspection To be delivered Inspection report including a coloured deviation map in the form of a PDF file (screen shots) and also an interactive 3D viewer. Quality control can be divided into 3 steps: • 3D digitising (ATOS scanner and/or TRITOP Optical 3D Coordinate Measuring Machine) • 3 dimensional re-alignment of the point clouds • inspection report (static deformation or under load) 3D Digitising Using the latest digitising techniques, we can model objects of widely varying shapes and styles (in-house or at your premises). Advantages • high accuracy • short lead times • particularly adapted to complex shapes • easy-to-understand, quick and global analysis Aim: comparing a physical part with the corresponding theoretical 3D file (or with another part). Our equipment can deal with your project, no matter what its size, from a watch to an entire vehicle. Reverse Engineering Piece of art Physical pattern • Mock-up / Mould • Production part • Vehicle • Sculpture • Prosthesis • One-off / rare part (in good condition or damaged) Small objects Fringe patterns 3D Scanning Optical (without contact) The point clouds obtained by sensing or use of the optical scanning system enable: • the creation of a 3D file of the part, • the direct machining of a copy of your pattern, • digital archiving, • dimension inspection, • the production of diagram showing the differences between the 3D file of the part actually digitised and the theoretical 3D file. • GOM Atos + Tritop (projection of light fringes and photogrammetry) • Atos SO for precisely measuring small objects Microtomography (X-rays) Reverse Engineering is done from the point clouds previously obtained from the digitising. This stage aims to obtain a surface file, usable by CAD packages. It then becomes possible: • to modify the geometric characteristics of your part, • recreate a construction history, • make drawings of your part, • develop a new part, based on the main features of the old one, • create a CAD design which will be used in the development and industrialisation of your products. You benefit from: • the most advanced solutions available on the market, • speed of execution, • precise metrology, • an advantage over your competitors. 6 3D Files • Point clouds Files in text format (ASCII) • Triangulated files Files in STL format Producing a surface diagram Software • Rapid Form • Pro / Engineer ISDX • Rhinoceros • GOM Inspect PRO • Surfacer Motor cycle engine Available file formats Reverse engineering increases flexibility, reliability and speed of development and reduces your costs and lead times. • IGES or STEP following a semi-automatic reverse engineering • Pro-Engineer or CATIA following a standard reverse engineering 7 Rapid Prototyping 3D Printing Rapid Prototyping Stereolithography (SLA) Need a functional prototype as quickly as possible? You have a CAD model of your project and you want a reliable, quick and efficient service to produce it? Initial offers you a range of technologies and a large variety of materials for greater flexibility in producing your product. Polyamide powder Alumide powder Stereolithography Glass-filled powder Stereolithography makes it possible to manufacture precise prototypes and complex shapes from photosensitive resins. Our range of machines and production capacity enable speedy production even of serial parts. Conscious of the urgency of your projects, we undertake to deliver in the minimum time possible. This is the most widely-known technology for obtaining physical models from a 3D file. Carbon-filled powder ABS (FDM) Intended for marketing presentations, ergonomic tests or the validation of a design, these prototypes can also be used as master model for vacuum casting. Fused Deposition Modelling (FDM) Transparent resin Fused deposition modelling or FDM produces parts in ABS or ULTEM with good geometric stability that are easy to prepare, paint or metallise. This technique is ideal for large parts with large surface areas and prototypes made this way can be used as functional and aesthetic models. FDM is an ideal solution for: • testing prototypes • obtaining finely-detailed high-quality parts, • manufacturing durable parts with good stability, NanoTool filled resin • producing shapes accurately (lids, shells, etc.) Laser in action SLA 5 000 Our machinery FDM Machine • Two SLA 5000 3D Systems capacity of 500 x 500 x 600 mm • Two EOS 400 SX machines capacity of 400 x 400 x 300 mm • One SLA 250 3D System capacity of 250 x 250 x 250 mm Materials used Large capacity 600 x 500 x 600 mm • White opaque ABS type resin • Flexible white opaque resin • Transparent resin • Stiff composite resin, temperature resistant up to 200°C. 8 9 3D Printing Vacuum casting Vacuum casting allows faithful reproduction of a pattern using a silicone mould. We produce your parts in polyurethane close to the specification material using gravity moulding in vacuum chambers. Applications • One UGM700 machine capacity 800 x 700 x 700 mm • pre-production for testing the market with your customers • Three UGM400 machines capacity 400 x 400 x 400 mm Casting From a stereolithography master we produce short runs in cast aluminium and various alloys, cast in plaster moulds. Our machinery • prototypes for mechanical, thermal or aesthetic validation CNC Machining • Materials: AG3, AS13, Zamak, etc. We then carry out any tempering and any post-machining. You can ask us to check your parts dimensionally or carry out an x-ray examination. Very useful for checking casings for various enclosures and engines; the parts can be used as production parts. • short runs for marketing • over moulding of inserts • Size of parts: from 10 g to 10 kg. Carters Materials used • various grades of polyurethane to meet your specifications: r igid, soft, dyed,transparent, temperature and impact resistant • medical and aeronautics approved materials • silicone • epoxy Cab trim panels Machining As a complement to additive manufacturing we also have comprehensive and up-to-date machining equipment. Using this technology, you can quickly obtain small runs of functional parts at very competitive prices. This is a great asset which enables the production of parts requiring particular precision and also the machining of certain materials which are only available for use with this technology. From your CAD files, we prepare the CAM tool files, then machine any type of material on CNC machines. Silicone mould • Ureol type machinable board • steel, • aluminium, • plastics. Machining remains a quick way of obtaining stylish mock-ups or prototype parts. Food industry Polyurethane part 10 11 3D Printing Selective Laser Sintering (SLS) Cleaning Our machinery More than 10 years experience in SLS linked to high-technology equipment enables us to assist you to make the best use of the benefits of sintering polyamide powder. • Two EOSint P730 machine capacity 700 x 380 x 580 mm • Three EOSint P380 machines capacity 350 x 350 x 600 mm • One EOSint P390 machine capacity 350 x 350 x 620 mm Your parts are produced by the building up of layers of molten polymer under the action of a CO2 laser, which enables the production of extremely complex geometries. • One EOSint P360 machine capacity 350 x 350 x 570 mm Our machines are equipped with an automatic feed system, ensuring an even powder mix. Alumide part Materials used We can advise you on the various materials to match each of your needs: The parts obtained have excellent mechanical and thermal characteristics close to the specification material. • natural nylon, • glass-filled nylon, This technology is ideal for functional or assembly validations. • aluminium-filled nylon, • carbon-filled nylon, The wide range of machinery and the variety of powders used guarantees a high level of productivity, allowing costs and lead times to be optimised. • flame-retardant UL94/V0/FAR25 nylon, Alumide parts for the automotive industry Some of them are certified for medical and aeronautics applications. Applications • mechanical, thermal, assembly and clipping validation, • resistance to severe impacts, • resistance to aggressive liquids: hydrocarbons, glycol, hot water, • maintaining parts, special machine parts, Machine preparation • complex geometry parts, not demouldable • thermoforming production moulds • large-scale mock-ups, The parts can be used unfinished or painted 12 • short runs of production parts 13 3D Printing Selective Laser Sintering HD (SLS HD) PolyJet: Multi-Material 3D Printing When you require very thin details on fragile, small parts you need high resolution. PolyJet 3D printing is similar to inkjet printing, but instead of jetting drops of ink onto paper, we jet layers of curable liquid photopolymer onto a build tray. PolyJet 3D Printing technology offers many advantages for rapid tooling and prototyping, and even production parts with astonishingly fine details, smooth surfaces, speed and precision. SLS High Definition -HD- offers 60 micron layers and 0.4 mm walls, i.e. half as thin as standard SLS. SLS HD is 4 times as accurate as standard SLS. This technology should be employed preferably for small parts requiring an optimal surface quality, such as connectors, figurines, jewellery, gears, complex geometries... Structure details Thanks to thinner layers and a smaller laser spot diameter, the results are more precise and the details substantially better. The process is ideal for small series. Connex 350 • Create smooth, detailed prototypes that convey final-product aesthetics. • Produce short-run manufacturing tools, jigs and assembly fixtures. • Produce complex shapes, intricate details and smooth surfaces. • Incorporate color and diverse material properties into one model. Ideal for prototyping multi-material products, finding the right shore hardness or reducing your time-to-market. Machine • CONNEX 350 • build tray size of 350x350x350 mm • 8 printer jets Applications • horizontal build layers down to 16 micron • rubber-like flexible parts • build resolution x and y: 600 dpi • parts with multiple tones and materials • precision X and Y: 0.2 mm Formiga P 110 Machine • Formiga P 110 - 220 x 250 x 330 mm Material • Nylon 14 Materials • gasket joints, shock absorbers, shoe soles... Bi-material • rigid white: VeroWhite + • flexible black - 27 Shore A: Tango black + Bellow Flexible • mix of VeroWhite + and Tango Black +: rigid grey or flexible black up to 95 Shore A • combination of flexible and rigid materials on one and only part 15 Rapid Manufacturing Finishing To enable you to have an idea of how your final part will look, we offer various types of finishings, such as: • a coat of paint, • a coat of transparent varnish or polish followed by a varnish to obtain the best transparency on a translucent stereolithography, Digital mock-up • careful preparation, followed by a coat of paint, Rapid Manufacturing, also known as Direct Manufacturing or e-manufacturing is a new way to produce parts or sets of parts. • screen printing, • vacuum metallising To make this possible we use rapid prototyping methods, apply stricter manufacturing procedures and, in particular, we re-design parts to re-size them in response to the new method of manufacture. • metal plating • impregnation to seal sintered parts, So, you will be able to: • design custom parts • develop your product quickly, Finishing can be in several colours and textures: satin, mat, smooth, fine grain, medium grain, etc. • modify and develop the design of your product at any point in time, INITIAL is equipping and structuring itself in response to an increasing number of developments in these technologies. • manufacture your parts directly from a 3D file • obtain your parts without production tooling • produce extremely complex parts, • reduce costs for short production runs. Alumide production The main areas we aim to improve: • parts design, • productivity, •m  achine capacity, in order to be able to manufacture large parts, • the speed of production, • the quality of parts, Complex cobalt-chrome parts Metallised parts 16 Metal plating Exhibition mock-up • the range of choice of materials. • traceability 17 Metal ALM Metal Additive Layer Manufacturing (ALM) With an experience of more than 10 years in Metal Additive Manufacturing, INITIAL has been using Direct Metal Laser Sintering (DMLS) aka Selective Laser Melting (SLM) since 2002 to directly build your parts or your mould inserts. INITIAL houses one of the greatest production capacities in Europe, meaning responsiveness and versatility in terms of materials used. Series parts Post-process • How does it work? Starting directly from CAD files, we build your parts layer after layer. Metal ALM is a revolutionary technique: it uses a laser to sinter or rather to fully melt powdered metal in layers down to 20 microns, thus offering an excellent, detailed resolution. We have a complete workshop for post-processing: • Since the material is fully melted it allows mechanical properties similar to parts made by casting or machining. Parts built from Metal Additive Manufacturing can be machined, spark-eroded, welded, micro shot-peened, polished and coated. • for removing supports: CNC, EDM, milling, digital-lathe • for ageing: furnaces • for finishings: leather mop for polishing • Ideal for manufacturing one-off complex parts or short-runs in short leadtimes, this technology opens up new opportunities and new markets. Applications • production of complex detailed shapes • manufacturing of geometries that are impossible to build any other way (e.g. conformal cooling) • one-off and short-runs Materials and application examples Under Nitrogen: • Maraging Steel MS1 Can reach 54 HRC after age hardening. Applications: mould inserts for conformal cooling, accurate parts, mechanical parts, aeronautics. • StainlessSteel PH1 hardenable up to approx. 45 HRC, very high strength, magnetic. Applications: functional prototypes, mechanical engineering, medical technology. • StainlessSteel 316L Corrosion-resistant. Applications: medical, lifestyle, aerospace, foodand skin-contact. • CobaltChrome MP1 High mechanical properties in elevated temperatures <1150°C, hardness 40-45HRC, nickel-free. • Inconel IN718 • Inconel IN625 • Hastalloy X Nickel alloys showing outstanding mechanical properties, corrosionresistance, excellent cryogenic properties. Applications: aerospace, motorsports, industry, series. Applications: biomedical, medical instruments. Acoustics 18 • customised products (e.g. medical) Under Argon: • Titanium Ti64 Light weight with high specific strength, corrosion-resistance, very good bioadhesion. Applications: aerospace, motorsports, biomedical, functional prototypes, series. • Aluminium AlSi10Mg Alloy used for cast parts with thin walls and complex geometries. Good strength, hardness, parts subject to high loads, good thermal properties, low weight. Applications: aerospace interior, motorsports, automotive, functional prototypes, series. • competitive lead times as compared to conventional methods • selection of high performance alloys • technology with high added value enabling cost reduction Complex geometries Capacity • 2x EOSint M270: build plate - 250x250x215mm running under Nitrogen. • 1x EOSint M270: build plate 250x250x215mm Xtended running under Argon. • 2x EOSint M280: build plate 250x250x320mm Nitrogen + Argon • 2x IPCM to guarantee powder quality and monitor granulometry (grain size) Use Metal ALM: design in a different way, produce diversely, be ahead of your competitors. 19 Metal ALM Designing for Metal Additive Layer Manufacturing (ALM) Conformal Cooling Laser Metal ALM is a very specific technology that replaces no other. Engineers need to think differently. Design should integrate both the specificities and advantages of the process. Metal ALM is similar to welding. Parts are built by layers on a metal plate and are later removed via EDM or manually sawn-off. Conformal cooling channel is a cooling passageway which follows the shape or profile of the mould core or cavity to perform rapid uniform cooling process for injection moulding. As a result there is always a post-processing step required, that can prove to be complex. It is the dream of all mould-makers to have cooling channels running in areas of the mould that are unreachable with conventional machining. It is important to note that inner stress due to temperature changes and welding of metal particles can cause warping. This needs to be anticipated. Our engineering team is highly qualified for designing or redesigning your parts for the Metal ALM process, allowing better results. Layer-manufacturing makes it possible to build complex double or even triple channels, coils, tab gates, etc. Some design rules • avoid parts with holes or functional details on two main sides, since the side facing down on the build plate will be full of supports that will need to be removed. It is now possible using Metal ALM to build inserts including specific circuits in order to evacuate as many calories as possible. Supports • avoid horizontal areas for surfaces facing towards the build plate. Maraging Steel MS300 can reach 54 Hrc after ageing. Our in-house installations are equipped with a complete mechanical workshop, an injection moulding facility and DMLS machines to significantly reduce lead times. Injection moulding machine Thermal control Advantages • highly efficient thermal regulation • add radius whenever possible at every section change. • homogeneous thermal process of inserts • add material allowance for finishing operations on areas or dimensions with very tight tolerances. • reduced cycle times • optimised material performance • remember that loose powder will need to be cleared off from inside the part. • avoid copying/pasting parts designed for other manufacturing methods such as bending, embossing, machining, casting... This is the most recurring error. 20 • improved moulding conditions • more stable moulding process, hence geometries • reduced sink marks Build orientations Mould Cooling channels 21 Tooling / Injection Tooling / Injection Moulding Injection As an indispensable complement to our mould production, we offer you a range of adaptable and modular plastic injection moulding machines, ideal for producing small runs. We validate or produce your product in the final material and at an attractive price. Prototype moulds Our machinery To validate your injection process, produce a pre-production batch, obtain final approval for your parts, prototype tooling allows you to quickly obtain short runs of parts in the specification material. 4 Injection moulding machines • 1x 50T hydraulic • 2x 50T electrical • 1x 150T electrical Cavities The flexibility of our structure, associated with innovative technical resources, allows us to produce short runs of your injected parts in a very short time and in complete confidentiality. For very complex small parts the cavity is made using DMLS, thus reducing production time by up to 50%. Thermoplastics are transformed under typical conditions for production parts and they are quality controlled according to your needs. Prototype tooling is the ideal process for: We put our experience in the use of highly technical materials at your service: • Polyamide, Ixef, PC, • low investment, • Peek, • obtaining high-quality final parts, • Sebs, Santoprene, • the production of technical parts in the specified materials • Acetal, Polypropylene. • the rapid introduction of your parts on to the market. The flexible way we are structured allows short production runs and reduced delivery times. Pre-production moulds /Production moulds Prototype mould With INITIAL you will find a responsive partner who listens to your needs and can look after the whole of your project. Production of thermoplastic injection moulds of various sizes with automated or hand-loaded platens. Specialists for several years in pre-production and short run moulds, we are accustomed to parts and materials of a technical nature. There are two methods we use to produce a mould: • removing material - machining an aluminium alloy for short runs, - machining stronger, pre-toughened steel from 110 to 140 kg, for longer runs and abrasive materials. • adding material - mould cavities by Metal ALM for small parts with complex geometry, 22 Short-run production mould - DMLS enables the production of cooling channels closer to the geometry of the parts, thus making possible a reduction in the cycle time thanks to better regulation (conformal cooling). 23 A GROUPE GORGÉ COMPANY Head office 4, route de Branchy B.P. 105 F-74600 Seynod Tel. : +33 (0)4 50 69 33 73 Fax : +33 (0)4 50 52 00 61 [email protected] www.initial.fr