Project omniroll

Volume: 3 molds
Lead time: 12 weeks

Job definition:
makeover and further development of a nearly 30-year-old plastic part.

Difficulty:
The "omniroll" assembly consisted of one case and 6 rolls, which were produced in 2K technology.
The first component was a core produced from Nylon 6 that was then over-moulded with different polymers, usually Nylon or TPU, depending on the application area of the particular roll.
One particular difficulty was the zero-play demand for the 2k rolls in all 6 case positions; another one was the high demand on the stability of the final assembly. Because of the part age, there were no existing product data, specification sheets and drawings. This was extremely difficult, as the client wanted to build the moulds in China.

Course of action:
After building the part data, we analysed them with warpage analysis, as well as finite element analysis, to optimise the part according to our customer’s demands. We then handed over the final part data, which already contained all the warpage and shrinkage data, to the Chinese mould maker with an additional specification sheet. In addition to the project management, we participated in the first sample process at the mould maker’s production plant in Shanghai. After some minor corrections, we then handed the moulds, sample reports, process sheets and electrodes to our customer.

Results:
Due to the optimised data and the close connection with the mould maker during the mould making process, we were able to provide usable parts from the first sample process. The stability of the product was much higher than the predecessor models.