Cables and chains overmoulding
The project
In order to optimise costs on powder conveying equipment, we developed a tailor-made technical proposal: injection moulding of engineering polymer plates onto cables and chains. A functional innovation that has improved performance and durability while reducing overall costs.
Sector:
Technologies involved:
Design and DFM, Injection moulding, Mould construction, Overmoulding
Initial requirement
In the context of powder transport plants, the customer was facing costs that were no longer sustainable. It was necessary to intervene with a system capable of reducing them, without compromising the reliability of the existing lines or the operational performance of the plants.
What was the problem?
Contain excessively high operating costs due to the frequent replacement of components and the complexity of the solutions adopted so far. It was necessary to find a way to significantly reduce economic outlay without jeopardising continuity of service or the efficiency of existing installations.
What was the client looking for?
An effective, yet economically sustainable solution that could maintain or improve plant performance. It was essential to find an alternative to traditional methods that could reduce costs in the long term.
The challenge
The real crux was to be able to cut the budget without compromising on performance. What was needed was an innovation that could be integrated into existing systems, improve component durability and simplify processes at the same time.
- Excessively high investment due to frequent replacements.
- Complexity of traditional solutions.
- Need to maintain operational continuity of installations.
- Search for an action strategy compatible with existing cables and chains.
The process
The complexity lay in adapting an advanced technology, such as injection moulding, to a specific type of mechanical support such as cables and chains. The process was tailor-made, coordinating each step with the aim of ensuring precision and repeatability in production.
We thoroughly studied the operating conditions of the installations involved, assessing the interactions between chain, plate and material to be transported. The layout was designed to ensure dimensional compatibility and mechanical stability, without compromising installation flexibility.
Specific engineering polymers were selected for the intended use, with a focus on strength, durability, and wear behaviour. The possibility of varying the material according to the application made the project versatile and customisable for different needs.
The mould was designed in-house with specific adaptations to allow direct overmoulding on elements such as cables and chains. The configuration was developed to ensure stability during injection and facilitate reliable and repeatable production.
Production takes place by injection moulding on existing substrates. The integration of plastic and metal is guaranteed by careful management of the process parameters. The result is a one-piece, stable, durable part, ready to be fed directly into the line.
The result
The proposal resulted in significant cost reductions while improving the overall performance of the plant. Direct overmoulding has simplified production, increased the durability of components and introduced greater flexibility in the use of technical materials.
- Reduction in production and maintenance costs.
- Increased component durability compared to the previous solution.
- Possibility of customisation according to use.
- Leaner production path, with less ancillary processing.
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