Hong Kong-based company offers a mould and die design and manufacturing service to Western quality standards, but at 'Made in China' prices.

FortunTec Solutions, a Hong Kong based company, operates a specialist mould and die factory in southern China. the company designs and fabricates moulds and dies to western quality standards at 'Made In China' prices. The annual turnover is 700 sets of moulds and dies.

We utilize CAD/CAM facility to speed up the fabrication process.

Our project engineers handle your projects from engineering design, through fabrication, debugging and shipping.

Our project managers are able to communicate with you via email and phone calls to update you on project progress, technical problem solving and respond to engineering changes you wish to make.

Measurement of moulds and tooling for modification or repair is done automatically at a German automotive plant, the system delivering complete 3D data sets.

Since September 2004, Volkswagen (Kassel, Germany) has used a COMETVarioZoom 2M sensor and the COMETinspect software for 3D coordinate measurement and inspection applications. In the moldmaking and tooling division of the company's production unit in Kassel, die copying and die spotting models are developed for the application of corrective measures or changes to the shape of the tools (e.g, if tools are subject to wear and tear or in case of upcoming product changes). For an effective acquisition of the 3D data, the tool/model parts are positioned on a COMETrotary rotating table - the measurement is then done automatically and delivers complete 3D data sets, which are stored for successive reproduction of the parts with highest contour accuracy.

For an inspection of the dimensional accuracy when starting the production of initial tool models, the measured 3D data can be compared online with the existing CAD data sets.

Latest CAM software has given a mould maker the ability to machine pre-hardened stock, reducing bench times from 1 week to 1 day, realising biggest savings with multi cavity tooling.

NC Graphics' DEPOCAM and toolmaker software has played a key role in the business plans of East Kilbride based Anderside Tools. In 1983 Hugh McKinnon the Managing Director had a vision to create the first specialist mould making company in Scotland, using his experience of procuring moulds to provide the type of service he had been looking for in his position as technical director of a moulding company. Unique in 1983, he offered his clients a complete service which included accurate quotations, feasibility studies, mould design, mould manufacture with modern CNC machine tools, and in-house mould sampling in a professional and clean environment.

Taking this a stage further, he ensured that the moulds were designed with the correct fixings and water connections to suit exactly the moulding machine the customer intended to use, ensuring new tooling had been properly tested and could go directly into production.

This policy paid off handsomely for Anderside Tools.

12 years ago it doubled in size, going from 6000 to 12,000ft2 and invested GBP 1million in new equipment as part of a 3 year business plan, which in practice was executed in 18 months.

This was in response to the growing complexity of plastic parts with freeform surfaces demanded by customers such as Hoover, and the aim of Anderside Tools to bid for complete suites of tooling from major customers.

DEPOCAM and ToolMaker were a crucial part of this plan.

Hugh McKinnon explained, 'The NC Graphics software enabled the efficient use of the new CNC machine tools and EDM die sinkers purchased as part of the expansion.

It streamlined the programming technology, and opened up new opportunities for the machining of ambitious shapes, providing a shop window for customers, and encouraging major clients including IBM and Compaq to order larger tooling packages.' Hugh McKinnon also formed Origin Precision Mouldings to provide a product moulding service for his clients, further enhancing the principle of a complete service.

2001 saw history repeating itself for Anderside Tools.

New challenges from the Far East prompted a further GBP 1million investment in new technology to improve efficiency and competitiveness by the introduction of High Speed Machining (HSM), and the latest EDM die sinking and wire erosion equipment.

The three new Mikrons, HSM700, VCP710 and UME560 provided spindle speeds up to 42,000 rpm and required specialised and reliable toolpaths.

Additional DEPOCAM seats enabled very small tools down to 0.3mm diameter to be used for engraving graphite and 0.5mm tools to be routinely used in steel.

Lights-out machining is a normal part of the working week, so the reliable toolpaths created by DEPOCAM were essential for success.

Ian Ferguson CNC Programmer for Anderside Tools said, 'The moulds are high value items, so we cannot afford to have errors in the machining, our move to HSM was painless with DEPOCAM.' Anderside now machine directly into hard material using HSM techniques.

Previously they would have vacuum heat treated the mould before bench finishing the shut off faces.

DEPOCAM has given them the ability to machine these directly in the hardened state, reducing bench times from 1 week to 1 day, with the more complex and multi cavity tooling providing the biggest savings.

Ferguson commented, 'The two halves of the mould fit together perfectly straight off the mill.' Further reductions in hand finishing are achieved by locally machining the ends of the nitrided ejector pins assembled into the tool.

DEPOCAM and ToolMaker have also provided economies in the EDM process.

Far more material is removed during machining, with the ability to use smaller tools.

The result has been a massive reduction in the number of electrodes required.

They are either completely eliminated, or they need to remove much less material.

In addition DEPOCAM, with its ability to reliably drive very small diameter tools, enables much greater detail to be incorporated into finishing electrodes.

Throughout the process, Anderside use System 3R electrode holders on its Agie Agietron and Sodick multi-station die sinkers, enabling it to transfer the datum from ToolMaker and DEPOCAM through to the machine tool and the EDM machine, ensuring everything lines up perfectly.

Standardisation on one CADCAM software solution has allowed a Brazilian mould maker to maximise the quality of the tooling it produces and so help improve the standard of many Brazilian toys.

Standardisation on Delcam's Power Solution CADCAM software has allowed Brazilian mould maker Fagmol to maximise the quality of the tooling it produces and so help improve the standard of many of the toys produced in Brazil. The significant improvement in the quality of toys manufactured locally has meant that the Brazilian toy industry should turn over US$ 336 million during 2003, a 75% increase compared to 1996. In addition, toy exports should reach the US$ 20 million during the year.

Fagmol, which is based in the city of Americana in Sao Paulo state, is one of the country's leading mould tool manufacturers specialising in the toy industry.

The company was started in 1991, when the founders rented part of a friend's shop floor, equipped with a milling machine, a grinder and a drilling/milling machine, all manually operated.

Subsequent acquisition of advanced CNC machinery and state-of-the-art software, together with intensive staff training, has given the company both the experience and the technology to offer a complete product development service, from the conceptual design of a new toy through to moulding trials.

'We can develop new designs, either by manual modelling or by computer-aided design with our seats of Delcam's PowerSHAPE hybrid modeller.

We can then design and manufacture moulds using PowerSHAPE and the PowerMILL CAM system, and, finally, we can undertake mould trials for injection moulding machines with a clamp force of up to 150 tonnes,' claimed Antonio Carlos Fagionato, Fagmol's Managing Director.

'This allows us to meet 90% of the local toy industry's requirements.' 'The toy industry accounts for around 85% of our production.

This includes supplying the five most prestigious toy manufacturers in Brazil.

The remaining 15% is related to maternity products, such as baby baths, baby walkers, etc,' added Fagionato.

During 2003, the company produced around 40 moulds, including examples up to six tonnes.

According to Production Manager, Alexandre Tadeu Fagionato, Fagmol 'was the first mould maker in Brazil to use the PC-based version of Delcam's software in 1996.' The initial period of adaptation with the software technologies was not exactly easy.

'When we installed our first CNC milling machine, back in 1994, we were told our productivity would drop at first - that was precisely what happened,' recalled Fagionato.

'When we implemented our first CADCAM seat, we also had a drop in productivity.

The cultural impact was enormous and it changed our way of thinking.' However, he added; 'Had we not made those investments, we would probably not be here today.' A strong commitment to staff training was essential in gaining real benefits from its investments.

Fagmol still believes that having the most advanced technologies available is of little use unless its staff is properly and regularly trained.

'We have made great progresses as a company but so has the Delcam software,' said Fagionato, emphasising that some current projects, with rigorous technical requirements and very short lead times, would have been impossible without Delcam's modelling and manufacturing software.

Fagmol is still committed to further growth and investment.

A supplier of innovative plastics technology, now offers a fully automated solution of flex foil injection moulding assist customers from conception development to serial production.

Quarder Werkzeugbau in Germany, supplier of innovative plastics technology, now offers a fully automated solution of flex foil injection moulding. Quarder not only produces the injection moulded products, it also puts the needed MID-Technology (Moulded Interconnected Device) at the customer's disposal. The company is able to assist customers from conception development to serial production.

Quarder builds fully automated product lines for MID-parts in large series such as door lock housings, gearbox cases or multi media cards.

For these products flexible polyimide circuit foils are inserted in a plastic injection mould and overmoulded with plastic.

Directly after this follows an automatically pick-and-place and soldering process of micro switches.

The 100% final quality test is also fully integrated in this patented method.

Fast and economical The flex foil method is faster and more economical compared to traditional PCBs (Printed Circuit Boards).

Due to the flexible circuit foils one can realize a multitude of electrical circuit layouts in a three-dimensional part with a high degree of design freedom without need of intermediary connectors.

For the same functionality this technology needs less building space and less process steps during production.

Smaller presses with less power and less machines in the production line reduce the fix and variable cost significantly.

Changes, for example a different circuit layout are easily implemented and incur low change costs at the flex foil.

3D flexibility Products with qualitatively higher usage properties can be realised.

Replacing injection moulded metal pressed screens through flexible circuit foils avoids limitations in regard to the three-dimensional product design.

Because of this, design and production of complicated applications, that until today appear impossible, become feasible.

Hence, a lot of precision miniaturised applications circuitry of 55 microns width become only possible with flex foil technology.

'More and more electronic components are integrated in cars, but at the same time building space is reduced', says general manager Martin Quarder about the present situation in the automotive industry.

In the computer industry minimising building space can only be achieved through injection moulded flex foil technology in combination with 3D design freedom.

'With these high data rates laser transceivers with flex foil are the connecting element of the future.

If put on circuit boards, currently one can pump 2 Gigabytes per second through Fibre Optics Cable'.

Rough and tough With flexible circuit foils and its thermoplastic injection moulded coating from Quarder which ensures that the foil is being protected, an IP 67 protection is no problem.

On the opposite, traditionally stamped PCBs or injection moulding with affixed flex foil are never completely sealed without any problems.

Additional advantages of the flexible PI-foil include resisting to high temperature which withstands temperature peaks of 310 degrees Celsius for a short time and 150 degrees Celsius continually, as well as the possibility to use different contact surfaces such as gold, tin and copper.

All usual soldering techniques can be used.

Because of the arrangement of the contacts on both sides of the foil a high placement density is possible and that with low overall height.

Unique 'At the moment we are the only company in the world which produces in this fully automated method on such a large scale', says Martin Quarder.

'In a few years it will be standard technology.

However, Quarder constantly works on new innovations; because there always will be more and more complex applications that demand more design freedom'.

For low pressure moulding techniques, Kistler has developed new sensors with a resolution four times higher than standard sensors and with a measurement range of 0 to 200 bar.

Low-pressure techniques such as injection-compression moulding,foaming and in-mould decorating have been gaining in importanceas methods for enhancing injection-moulding processes. Industrialapplication of these techniques, however, is more complex thanstandard processes. Mould cavity pressure measurement providespractical help for mould sampling, large-scale productionmonitoring or for quality documentation.

To meet the specialrequirements of low pressure moulding techniques, Kistler hasdeveloped new sensors with a resolution four times higher thanstandard sensors and with a measurement range of 0 to 200 bar.With front diameters of 2.5mm and 4mm, the new sensor dimensionsare equal to those of standard sensors allowing existing mouldsto be easily upgraded.

The sensors are use with single-wiretechnology and are compatible with standard cables and chargeamplifiers, allowing major savings in mould engineering andmaintenance.

The sensors with product numbers 6177AE (frontdiameter 4 mm, sensitivity 45 pC/bar) and 6178AE (2,5 mm, 10pC/bar) are available now.