Part Design & Development
We at Kaizen having expertise of 18+ years in the field of thermoforming, share our technical expertise to various clients. From our past experiences and learnings, we share our valuable insights and support our clients in various small but important technical details
Design Enhancement
Designing and development enhancement needs expertise. It requires experience and technical knowledge about various aspects of the product working. We being passionate at Kaizen about thermoforming and having industry expertise for more than 18 years, we help our clients in designing an industry ready products
Tool & Trimming Fixture Design
Five-axis CNC trimming produces parts with repeatable, close tolerances. There are several keys to achieve consistent and accurately trimmed parts. Most thermoformed parts are made of softer materials that react well to O-flute style tooling. For thermoforming, the most common choice has been single edge and double edge straight tools. Single edge tools typically feed the easiest and double edge tools will usually give a better finish and allow faster feed rates in the hands of an experienced operator. At Kaizen our expertise and experience comes very much handy in providing quality trimming.
Prototype Tooling/ Rapid prototyping
Designing a prototype requires a lot of use case scenario building and testing. Creating a testing environment requires a lot of expertise and efforts. We at Kaizen have both of these: Expertise and Passion to put required efforts. Developing a prototype gives an opportunity to show creativity, innovation and conceptualization. it’s always exciting to see your idea transformed into a fully functioning device, item or tool.
Prototype Development
As we at Kaizen believe in delivering the quality products we require extensive prototyping. Virtually any thermoplastic available as extruded sheet stock may be used to thermoform prototypes or manufactured parts. Since vacuum forming parts takes only minutes, prototypes are done in less time than it would have taken to create a fibre layup tool.
Production Tooling
Making a tool for Vacuum forming/Thermoforming requires real expertise and experience. Tool selection depends upon the type and thickness of the used Plastic sheet, product quantity and dimensional accuracy requirement. Production tooling is done on high quality Aluminium blocks and plates. For large size moulds, aluminium casting is done from a wooden casting pattern. Dimensional machining and finishing of the casted mould will be done on various machines.
Material Selection
When it comes to use of plastic thermoforming materials, one of the greatest advantages is that they can be manipulated and alloyed at the polymer level as well as being co-extruded to produce a multitude of variations. Below is a list of the common tests that are performed on each plastic thermoforming material product, a description of what is measured, and how it should be used to assist in material selection.
Process Analysis & Improvement
In today’s fast paced world, process improvements and analytical approach for your businesses and its processes are very critical. There are various ways to improve your processes. We at Kaizen believe in 5 simple steps:
1. Modernization of equipment Older machines that are not running at peak could be costing you time and money due to decreased performance, slower cycle times, higher energy use, decreased flexibility and ever increasing maintenance costs. Modernizing your existing equipment with marginal capital investment will quickly improve your productivity by greater output and reduced downtime.
2. Controls upgrade Installing an integrated modern control package will eliminate the anxiety from the above scenario while improving performance of your equipment.
3. Ovens and Zone Control Creating different heating zones can provide greater control, preventing sheet overheating and increasing adaptability for new products. Replacing old components with newer technology allows for more accurate material heating with less guessing, resulting in more accurate forming that results in higher quality foam trays.
4. Quick set up and moulding tools Incorporating alignment pins into moulds assures “no guess” alignment accuracy. Running stops insure that the mould gap is ideal for your sheet thickness. Quick change mould inserts can reduce a two hour set up down to a matter of minutes.
5. Improve quality and scrap reduction Incorporating photo eye references within the mould will satisfy the need for accurate trimming. Adding features to the mould to create stiffness to the web will improve guidance and will also contribute greater trim accuracy. When troubleshooting quality issues, individual numbering of the mould cavities may help identify the problem cavity.
Multi-Axis Programming & Support
Multi-Axis Programming Movable-bridge machining centres specifically designed for high speed processing of composite materials and light alloys, providing exceptional motion dynamics to ensure high productivity. The advanced structural design avoids machining vibration and achieves excellent finishing quality. It allows the user to achieve the maximum material removal rates from a given surface simply by specifying the most suitable adaptive strategy in the part program. Adaptive Technology allows a complex surface to
be produced in significantly reduced cycle times without reducing the surface quality or accuracy.
If your project involves cut-outs, edgings or twisty openings which require a high level of precision, we have what you need. Our specialists in multi-axis programming with the latest technology serves your purpose well. We use your 3D files or create computer files to ensure precision and a high quality finished product.
Series Production & Assembly
In process manufacturing, the finished product is usually produced in bulk. Processing different parts simultaneously and assembling them once they are ready requires a lot of process synchronization. When we at Kaizen have expertise in perfect proto typing and have industry experts and well experienced teams we can easily turn the prototype into a mass production and assembly. Prototyping may have many smaller imperfect processes which requires to be perfected in case of requiring the mass production. Here the experience and expertise of Kaizen team comes into the picture.