In order to meet the project requirements of its clients, ETMA has created an exclusive system that customises the offer of its services. This system is the 10 Integrated Production Processes, which includes the Prototype process.
In this article, we will describe the different details regarding this production process, among which its utility and advantages, as well as the steps ETMA takes internally whenever a new project is received.
WHAT IS THIS PROCESS?
In the Prototype process, we start with the project needs and objectives of each client, using hardware and software that supports the project and the development before the serial production to manufacture prototypes and pre-series.
ETMA presents, therefore, the ability to produce prototypes and small series through the development of the project and manufacture of soft tools for the production processes:
- Stamping
- Wire forming
- Cold forging
- Turning
WHAT ARE THE ADVANTAGES?
The advantages of the ETMA Prototype process include:
- Agility in development – the possibility of creating prototypes and pre-series allows the client to validate and adjust the design before the large-scale production;
- Flexibility – through the manufacture of soft tools, ETMA easily adapts to the specific needs of each project, making changes and quick improvements possible;
- Risk reduction – the prototyping stage enables the identification and correction of potential design issues, ensuring that the serial production takes place without unforeseen events.
MANUFACTURE OF SOFT TOOLS
ETMA stands out in the production of metal parts, through the use of advanced processes of metal sheet forming with specific tools, known as soft tools. This method is highly effective to create prototype parts or produce small series.
Therefore, the use of soft tools provides a quick and flexible approach, making it the ideal solution for clients that require agility during the prototyping stage or for small productions.
Furthermore, ETMA is able to support the pre-series stage, enabling clients to test and adjust the design of the part before going to large-scale production.
This way, ETMA positions itself as a trustworthy partner in two main areas:
- Prototyping and small series: perfect for clients who need to test the design or require a limited production;
- Pre-series: a crucial stage to analyse the feasibility of the part before starting the serial production.
Production history
THE RIGHT PROCEDURE FOR PROPER EXECUTION
To ensure an efficient execution of the Prototype process, ETMA follows a rigorous procedure, which includes the following steps:
- Project analysis – evaluation of the client’s instructions and requirements;
- Development planning – definition of stages and schedule for the manufacture of the prototype;
- Prototype production – use of soft tools and specific equipment to manufacture the parts;
- Tests and adjustments – verification and introduction of the necessary adjustments in the prototype;
- Approval and delivery – presentation of the final prototype to the client for approval.
ETMA’S TEAM
The demand for tailored solutions, that comply with the requirements of each client, involves the development (comprised of engineers and specialised technicians) and sales teams, who share knowledge and experience with the client, resulting in synergies that are mutually beneficial.
A highlight goes to the Prototype Team, who plays a key role with ETMA’s clients, providing guidance regarding the best production and development plans for the requested parts, as well as their improvement.
When starting a prototyping project, you will have direct contact with a technical manager that:
- Monitors the project;
- Directly responds to any technical questions that you may have and meets the prototype manufacturing deadlines;
- Supports and helps you with technical requirements, both for new parts and changes in existing ones.
SOFTWARE
Software used to develop projects:
- Siemens NX
- AutoCAD
- PCam
- FEATURECAM
- Fusion 360
EQUIPMENT
With a dedicated production area of 620 m2, these are the main machines assigned to production in the Prototype sector:
- CNC Mikron VCE 800 W 3 axis
- CNC DMG CMX50 5 axis
- CNC DMG DMC 635V 4 axis
- Lathe
- Flat grinders
- Cylindrical grinder
- Fiber laser machine 3KW
- Deep drilling machine
- Column-type drilling machine
- Wire erosion machine (AGI-Fanuc)
- Penetration electro-erosion machine
It is also important to mention the use of other complementary equipment, namely:
In the Quality Laboratory:
- Profile projector
- Renishaw Equator 300
- Hardometer
- Rugosimeter
- Vision Engineering Xpress
- Mitutoyo Quick Vision
- CMM
- Profilometer
And in the production support:
- 63 /80/100-tonne press
- Balancing machine
- Manual or electric press brake
- Laser engraving machine
- Tumble blast machines
- Hydraulic press
- 3D printer
- Machining centre
- Electro-erosion machine
- CNC lathe, grinder, laser cutting…
MAIN BUSINESS AREAS
ETMA Prototypes is a highly requested process by different business areas, including:
The Prototype process is, therefore, a very relevant process in all ETMA’s 10 Production Processes, contributing to a very high trade-off between the quality of the parts and resource savings and optimisation.
Click here to discover more about the ETMA Prototype process or download our brochure.
If you are interested in learning more and, eventually, talking to us about a project, please do not hesitate to contact us.
