During the reporting period a proprietary application software has been developed.
This application software optimizes the present die-casting predictive engineering FEM model, and is able to identify in advance “fracture lines” in the die in a run time shorter than five days (vs some weeks, today!). This application software is designed in a way that even technicians with no knowledge of materials science, FEM, thermal-structural, coupled analysis and fatigue calculations will be able to use it.
According to the plan, a prototype die, together with the die-holder, equipped with sensors that can detect real die-casting process data, has been designed, built and placed into operation. Pressure and temperature data, strain gauge signals and digital deformation were collected, with the scope to compare them with the theoretical data calculated using the new application software, and consequently to fine tune the theoretical model.
In addition, few dies built according to the “puzzle die” technique were built and delivered, for testing in operational environment, to two customers.
Data and technical results were collected and encouraged the customer to let us proceed with the design and construction of deeper puzzled dies.
These new dies were in one case already delivered to the customer and successfully tested, in an other case the dies were tested in house before delivering them to the customer.
Results were fully satisfactory
Finally, the application for the International Patent related to our new technique for dies’ construction (puzzle die) was filed; in parallel the application was filed for EU, International and Canadian Trademark “PUZZLE DIE DIVIDE ET IMPERA”.
In parallel, all marketing and commercial activities required to illustrate and promote the “puzzle die” innovation have been put in place: participation to specialized exhibitions/fairs, organization of specific events, direct contacts and visits to customers.
Furthermore, a dedicated webpage was added to the company website, together with a video illustrating the new “puzzle die” approach, which showed to be the most effective way to spread the idea.
In general, contacted customers have acknowledged and appreciated the benefits of “puzzle die” concept, and some of them have accepted and are willing to further develop the idea for some important high volume projects.
As a side benefit of the project, during the test on the Prototype Die, it was shown that the puzzle die can really be designed to produce 2mm thick parts that are currently considered not feasible in HPDC.
