Effective control of the design process

Designing plastic products has always been a challenge, with many of the finished products demanded today being complex in terms of appearance and functions. In this aspect, design technology has become as varied and efficient as well, providing much-needed control of the whole design process to ensure that the final output meets established standards.

A manufacturer of high performance electronic connectors relies on the VISI suite of CAD/CAM solutions to produce multi-impression moulds containing hundreds of tiny, difficult to manufacture features.

Part of the Vero Software Group (www.verosoftware.com), VISI is acknowledged as one of the world's leading PC-based CAD/CAM solutions for the mould and die industries. The company offers a unique combination of applications, fully integrated wireframe, surface and solid modelling, and comprehensive 2D, 3D and 5 Axis machining strategies with dedicated high speed routines. Industry specific applications for plastic injection tool design, including material flow analysis and progressive die design with step-by-step unfolding, provide the toolmaker with high levels of productivity.

VISI offers dedicated solutions that eliminate the links between varying software suppliers and the solid-to-surface or CAD/CAM geometry conversions required by traditional systems. Vero sells and supports its range of products through its direct offices in the UK, Italy, France, Germany, Netherlands, USA, Brazil, India, Japan, Korea and China, and through a comprehensive global reseller network across more than 45 countries.

Harwin Plc works with several VISI modules on its Gecko brand of micro miniature shock-proof connectors, which withstand extreme temperatures and are used extensively across a variety of industries including motorsport, energy, avionics, satellites and defence. Harwin is a manufacturer of standard interconnect components with a reputation for high quality and exceptional customer service. Harwin has been successfully manufacturing electronic components for more than 50 years, with products including: high reliability devices; RFI & PCB Hardware; and an extensive range of industry standard interconnection solutions. The company operates a continuous product development program.

Harwin Technical Communications Manager Ben Green says expensive electronic equipment has to work perfectly. “Whether it be on an aeroplane, on racing cars or in the driver’s helmet, in a down-hole drilling system, or a satellite application, they all require reliable connectors to ensure they are never going to fail.”

Many of Harwin’s connectors are made from PPS and Valox thermoplastic polyester resin. They are produced in 420 Stavax steel moulds designed and manufactured with a VISI suite comprising VISI Mould, VISI Progress, VISI Machining, VISI Electrode and VISI PEPS-Wire. Tool Designer, Kev Hunt, says some of the components making up their mould tools have a 0.2mm wall thickness, which they manufacture with graphite electrodes. “There’s no way we can get into such small areas with a conventional cutter, so we need to use electrodes and wire EDM technology. This produces excellent results because it’s consistent and controlled, giving high quality finishes with no imperfections in the mould that would be transferred to the moulded products.”

Real time view of components

Once a new connector has been designed iNi?o/a