CAE - Computer Aided Engineering
RP&M - Rapid Prototyping and Manufacturing
Excellent tools for increased productivity in development and manufacturing
Problem Status
Today, due to the pressure of international competition, new products must be more quickly and cheaply developed, manufactured and introduced to the market. Conventional development procedures are, in many ways, not able to keep up with today's innovation dynamics. In view of the shortened cycles of production and the increasing variations of more complicated products along with the increasing demands for quality, it is inevitable to improve the development procedures. Since most of the production costs are already in this phase, one can judge which rationalisation potential is at hand.
Users from varying branches have demonstrated that this potential will be introduced very effectively through the general use of CAE- (Computer Aided Engineering) along with RP&M- (Rapid Prototyping and Manufacturing) technologies. All businesses which use complex components in their products or production procedures and are ready to rethink their principles will profit from this technology. Investments in own ressources are not necessary, since all of the necessary performance is externally available.
Decisive advantages in time and costs through the objective application of CAE/RP&M technology
CAE/RP&M-technology offers tools and procedures which are excellent for the quick and cost-efficient transformation of marketable products. Nevertheless, it is insufficient to open the largest potential of these technologies through the isolated application of individual tools. The maximum effect to be reached is much more aimed at the individual service position through a combination of well-suited tools and general procedures, which the given knowledge in the business is able to externally utilise. Due to the variety of available methods and systems, as well as the rapid development and increasing complexity of these technologies, it will be more difficult to maintain a general view. It is, however, this comprehensive know-how which is necessary to be able to generally install or utilise computer based production measures with features such as design (CAD), calculation/simulation/virtual reality (CAE), generative (RP) and metal-cut (NC) production procedures.
Rapid Prototyping
In the past, it was especially the lengthy and costly creation of prototypes which was often a weak point in the production process. It is now possible, by means of generative procedures, to produce low-priced and stable prototypes within shortest time. All generative procedures, for example Stereolithography (SLA), Selective Laser Sintering (SLS), Cubital/Solider, Laminated Object Manufacturing (LOM) or Fused Deposition Modelling (FDM) demonstrate the fact that components with a desired geometric shape can be produced in layers, with very high precision.
Through this quick and low-priced automated production of three-dimensional structures with the use of CAD data, physical models are already available in the early stages of product development. These models are of valuable help with the conception of complex designs. They also help the designer work more efficiently and simplify the communication between other departments, customers and suppliers. RP-models are ideally suited for form and fit procedures such as the examination of tolerance, open rooms and ergonomics. Many industrial businesses have already successfully utilised this technology, which was first introduced in 1987 with Stereolithography.
Subsequent processes
It is not well-known that the subsequent processes which are established on base-models developed through RP-technology, create nearly fully complete components or small-series out of plastics, metals and many other materials. Through the evasion of the usual, very costly tools, you receive components which are most similar to the end product in geometrie, surface, size and material. The creation of highly complex casts (injection moulding, investment casting, sand casting, pressure diecasting, etc.) has been proven to be especially to your advantage. The use of metal-cut tools, which are very timely and costly to manufacture, are currently used in order to create prototype and pre-series components. In addition, these tools are, in many cases, highly prone to alteration. The retrieval of alterations is, however, again very costly and reduces the tools life cycle. In contrast, the RP-technology requires no tools produced via metal-cut. Thus, the production costs of prototypes, pre-series and small-series will be drastically reduced. Further changes in the components during the phase prior to production are able to be accomplished with relatively minimal costs. The tools used for mass-production are first finished only if the parts are really ready for production. RP-techniques are basically also suited for the production of tools utilised for mass-production (Rapid Tooling). Tools for the different casting procedures, sheet-metal transformation, warm transformation, etc., can also be manufactured.
Just imagine, you can already present functional components of your new development in a stadium, which, using conventional measures, exist only as sketches.
These branches profit from the advantages offered by CAE/RP&M technologies:
- Producers of generally more complex components
- Manufacturers of small-series (aerospace, racing, luxury articles, replacement parts)
- Model and form/mould manufacturers
- Tool manufacturers
- Foundries
- Industrial designers, architects
- Medicine, medical technology
Application spectrum:
- Development of more complex assemblies and parts
- Design models
- Presentation models
- Functional models
- Prototypes
- Pre-production series
- Small series
- Tools
Objective advantages:
- Market advantages due to the reduction of production time and cost
- First sample parts within days
- Finest visualisation possibilities and the avoidance of errors based on the early availability of models (preventative quality assurance)
- Parts for experimentation, montage and acceptance trials as well as for exhibitions already in the developmental stages
- Optimise function, design and ergonomic, increased innovation level
- Improved quality from the developmental stages through to completion
- Simultaneous engineering (construction, design, analysis, completion)
- Fast retrieval of modifications, iterative product optimisation
- Production method oriented design
- Low-priced tools
- Generally increase productivity with massive savings in cost and time in the developmental process and the manufacturing of prototypes and pre-series parts as well as by the completion of tools of mass production
These technologies will also help you to further improve your productivity and ability to compete in the market. All businesses which do not invest in own ressources have the possibility of utilising outsourcing as a means to utilise this technology in a quick and low-cost manner.
Thus, the time it takes for your product to make it to the market is drastically reduced. Savings of up to 50 percent in time and money is of no exception. The more complex your product is, the greater the savings.
The application of individual innovative technologies, does not, by all means, guarantee the quick, low-priced, customer oriented development of products with a close co-operation of all participants. More important is the flexible application of all available technologies across the spectrum, adjusted to the individual assignments. The assisting functions of information processing such as information highways, multimedia, and data bases must be also considered. We will gladly assist you with the individual elements of this technology, method, and organisation, in order to develop them into a specific concept and the realisation of product development. In addition, our goal is to fulfil your demands more successfully, while always keeping in mind the function, quality, time, and costs required with the manufacturing of the finished product.
We offer you...
Even if you already have experience in the application of CAE/RP&M technologies, or if this is the first time you want to utilise them, we offer you the necessary skills required to accomplish your tasks. Since our office offers specialised service and consultation, we will work towards gaining solutions to your problems in the area of CAE/RP&M technologies as well as production procedures.
Through the rejection of self-production, we are not limited to certain systems or methods. All established technologies are directly available. Thus, the best method comparable to your certain needs is put to use. We do not limit our selves to partial solutions, but rather work towards offering you thorough solutions and procedures which completely fulfil your rationalisation potential.
Even if you want to invest in your own ressources or want to utilise the wide-range of possibilities with the various technologies, we will gladly be of assistance. We will, together with you, develop individual concepts in order attain the best use of the technology. Consultation and project transactions are by all means absolutely neutral and under strictest confidentiality.
Our performance profile in the area of CAE/RP&M:
- Consultation, project management and engineering services
- Assistance in the area of CAE (CAD-geometrization, data conversion, calculation, simulation)
- 3D-design, photorealistic rendering, animation
- Production of models using RP/LMT (stereolithography, selective laser sintering, laminated object manufacturing, fused deposition manufacturing, solid ground curing)
- Manufacturing of components (design models, function models, prototypes, pre-series, micro-series) using a wide array of materials (plastics and metals) through subsequent procedures
- Procedure development for components and tools, development of concepts and demands specified by the customer
- Introduction of CAE/RP&M technologies as well as the development of certain resources in your home
- NC-pre and post processing
- Optimise information processing for CAE/RP&M tasks (ISDN, Internet)
- Technical documentations
- Multimedia-presentations on CD-ROM and Floppy disk
- Know-how transfer, market studies, bench marks, seminars, workshops
It is the fastest and not the biggest or financially strongest company which is successful tomorrow!
Please contact us if you want to profit from the advantages of this technology in your next project. We are gladly at your service and will offer you additional information. Most of our services are currently only available in Germany. However, we would greatly appreciate co-operations with specialised foreign companies.
Wolff Engineering
POB 850
D-32070 Bad Salzuflen
Germany
Tel.: +49 5222 95 96 43
Fax: +49 5222 95 96 44
Please use our reply form or send your Email to:
wolff@tech-mall.de