Our client, like many in the manufacturing industry, faced the challenge of boosting machinery performance without the significant expense of new equipment. To overcome this, they embarked on a series of R&D projects aimed at enhancing their existing machinery's capabilities. We collaborated closely, taking a comprehensive approach that tackled each problem in stages. These sub-projects not only delivered targeted improvements but also laid the foundation for future innovations.

Improving plastic injection moulding machines

A key focus was enhancing the efficiency of their plastic injection moulding machines. The goal was simple: increase the flow of pellets through the system to streamline production. The client designed and prototyped a 'collar follower' to integrate into the existing machinery, but the initial versions caused pellet contamination. This setback led to further iterations and material testing. After several adjustments, the final solution significantly improved performance, demonstrating the value of persistence in the R&D process.

Reducing manual intervention in paper rolling machines

Another critical project aimed to reduce the frequent manual intervention required for their paper rolling machines. Paper frequently stuck to the rollers, causing disruptions. To solve this, the client tested different materials and roller designs, refining prototypes until they found a solution that not only reduced maintenance but also increased the machine's overall efficiency. The result? Smoother production, less downtime and fewer manual fixes.

Lowering costs for paper printing machinery

Finally, the client sought to reduce the manufacturing costs of their paper printing machines without sacrificing performance. By exploring the existing structure, they developed a lighter, more efficient design. Rigorous testing ensured that safety and functionality were maintained, while production costs were significantly lowered—proving that innovation doesn’t have to come at a financial premium.

Our client embarked on an ambitious project to develop a milling machine with enhanced capabilities, specifically designed to manufacture supporting beams used atop large doors, like those found in airports. These beams, measuring 13 metres long with custom-drilled slots, posed a significant challenge for existing milling machines, which lacked the capacity to handle such large workpieces. The engineers sought to create a machine that could overcome this limitation, making the project a perfect candidate for R&D.

Designing a machine for oversized workpieces

A conventional solution would have been to design a machine with an oversized bed and spindle to accommodate the larger beams. However, this approach would have resulted in an excessively large and impractical machine. Since portability was also a key requirement for the client, this solution was ruled out early on. Instead, the engineers focused on an innovative alternative—adjusting the workpiece itself to allow the machine to handle the larger beams while keeping the machine compact.

Innovating to reduce machine size without compromising functionality

Through extensive trials and experimentation, the engineers developed a unique method of holding the workpiece that allowed it to be processed in smaller sections. Alongside this, they engineered a new cutting technique to improve the efficiency of machining the slots. However, the initial trials affected the tolerances, prompting further design iterations to develop a holder that could support the machine and maintain the required precision.

Our client set out to significantly enhance the lifespan and functionality of a tooling component used in producing angled coupling parts for underground sewer pipes. The existing component had design flaws that limited its efficiency and durability. The company identified the replacement of the existing inclined pin actuators within the mould tool as a key step toward improving both the pressing process cycle speed and the overall lifespan of the tool.

Redesigning mechanical elements for improved performance

The goal was ambitious: to fundamentally alter the mechanical elements of the press mould machine while simultaneously extending its lifespan and increasing its cycle rate. By replacing the inclined pin actuators with a hydraulic cylinder, the engineers aimed to create a more robust, efficient system. This transformation required more than just swapping components; it involved reconfiguring the tooling entirely to integrate the new, bulkier hydraulic system.

Overcoming challenges in system integration

The introduction of the hydraulic cylinder presented significant design challenges. Ensuring the machine maintained its functionality while incorporating this new component required a complete reorientation of the machine. The team developed several models, calculating and adjusting the machine’s clearances and adding ancillary parts to support the new system. The reconfiguration also included adapting the press core to the hydraulic cylinder and avoiding component extrusion, ensuring the machine operated smoothly despite the substantial changes.

Our client undertook multiple projects aimed at enhancing the performance of existing machinery and we adopted a holistic approach to their R&D claim, highlighting various sub-projects. These included improving plastic injection moulding machines, reducing manual intervention in paper rolling machines and cutting machining costs for paper printing equipment. By focusing on refining existing technology rather than purchasing new machines, the client aimed to develop solutions that could be applied to future models. In each case, their innovations built upon the industry baseline, where little information existed on potential improvements, qualifying them for R&D.

Enhancing plastic injection moulding efficiency

The first sub-project focused on improving the flow of pellets through the plastic injection moulding machine, boosting efficiency. The client designed and prototyped a 'collar follower' to integrate into the existing setup. Early prototypes, however, led to pellet contamination, prompting further iterations with different materials. Through this iterative process, the team successfully enhanced the machine’s performance.

Reducing maintenance in paper rolling machines

The second sub-project aimed to address the problem of paper sticking to rollers, which caused frequent maintenance disruptions. The client experimented with various materials and roller designs, eventually developing a prototype that significantly reduced the need for manual intervention, streamlining production.

Lowering costs for paper printing machinery

In the final sub-project, the goal was to reduce the manufacturing costs of paper printing machinery while maintaining its functionality. The team investigated the current structure, ultimately developing a lightweight design that reduced costs without compromising on performance or safety. Rigorous testing ensured all health and safety requirements were met.