Agenda 1 Group Overview 2 Focus on Sirone plant & our Core Business 3 Further information
Who we were – Our history The 1 st tool-shop 1968 Co.stamp was founded back in 1968. A small workshop with few employees, specialized in the manufacturing of die casting dies. Since then we have been proudly serving the HPDC market, in a costant effort to improve our know-how and expertise .
Who we were – Our history 1968 Foundation 1982 Purchase of first CNC milling machines 1994 First automotive die – Steering Housing 1999 Move to the new premises in Sirone (LC) 2003 Purchase and installation of the 1 st HPDC press, for our internal sampling dept. 2004 Acquisition of 49% of the shares of PAMA SRL 2011 ISO/TS 16949 Certification 2013 Opening and start up of new plant in Rivalta (TO), for plastic injection molds. 2014 New expansion of Sirone plant: rough cutting & drilling facility. 2015 Launch of new dedicated warehouse for finished castings. 2016 Takeover of PiQ2, company that develops simulation softwares. 2017 Horizon 2020 Award. Coming soon 14001 Environmental certification.
Who we are – The Group PLASTIC INJECTION MOLDS GROUP MANUFACTURING OF DIE HOLDERS
Who we are – Sirone plant 48 CNC milling machines 6 Drilling stations 9 Spark erosion machines 4 Turning stations 5 Wire erosion machines 3 Spotting presses 6 Grinding stations 19 Overhead cranes
Sirone plant - Capacity 440 Projects per year 190 New dies, 250 cavity replacements Modifications, refurbishments, Maintenance
Who we are – Turin plant PLASTIC INJECTION MOLDS 7 CNC milling machines 1 Drilling stations 1 Spark erosion machines 3 Turning stations 2 Spotting presses 3 Overhead cranes 2 Grinding stations
Turin plant - Capacity 185 Projects per year 59 New dies, 126 cavity replacements Modifications, Maintenance, Components
Who we are – Pama plant MANUFACTURING OF DIE HOLDERS 11 CNC milling machines 1 Turning stations 1 Grinding stations 3 Overhead cranes 1 Drilling stations
Pama plant - Capacity 310 Projects per year 120 190 New projects Modifications, components
Who we are – PiQ² THERMAL SIMULATION
Where we are – The Group
On-site support - Auburn Hills, MI - Thanks to our partners we can provide full after-sale support, on-site: Engineering changes Tool repairings Start-up assistance - Komaki-city - - Queretaro -
Worldwide agencies North America China Ltd - Kokomo - - Shanghai - Ariatech Co. Ltd Iran - Tehran - Protos Engineering Co. PVT. Ltd India Brazil - Mumbai - - Indaiatuba, San Paolo -
Revenue over the years – in k € 60.000 56.000 49.800 50.000 43.900 39.700 40.000 31.900 30.000 25.800 21.800 20.000 17.700 17.200 14.700 14.800 10.40011.80012.500 8.500 10.000 0 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
2016 Turnover – in K € 35.000 30.600 30.000 25.000 20.000 15.000 10.000 8.800 6.000 4.400 5.000 0 Die Casting Dies Plastic Injection Foundry Die Holders Molds
Personnel N° employees of the Group 228 Sirone HQ 168 Turin facility 35 3% 3% 4% Pama 20 17% Design PiQ² 5 5% Production 3% Administration Quality Sales Purchase Logistics 65%
Agenda 1 Group Overview Focus on Sirone plant 2 & our Core Business 3 Further information
Focus on Sirone Plant (HQ) Employees 168 SANDBLASTING, Workshop 10.150 m² FOUNDRY DEBURRING & STORAGE ( 6 ) Offices 1.830 m² OFFICE ( 4 ) CASTING QUALITY (3 ) FOUNDRY (29 ) WAREHOUSE (9 ) CAM( 6 ) ASSEMBLY / HOT SEMI FINISHING / SPOTTING ( 20 ) FINISHING ( 21 ) ROUGHING & DRILLING ( 15 ) PM & R&D ( 6 ) PURCHASING ( 5 ) IT ( 2 ) DIE QUALITY ( 5 ) GENERAL PLANNING ( 1 ) FRONT SERVICES( 3 ) CAM( 3 ) DESK ( 2 ) TECHNICAL ( 18 ) SALES ( 6 ) ACCOUNTING ( 4 )
Turn-key service Project management 1. Equipment manufacturing 2. Consultancy service from A to Z Design 1. Part codesign 2. Die design 3. Simulation work HPDC dies 1. Complete dies 2. Complete sets of casting inserts 3. Maintenance & refurbishment Try-outs / small 1. Samplings productions 2. Dimensional and metallurgical controls 3. Complete set-up process 4. Process development 5. Production of small batches & special series
PR JECT MANAGEMENT
Project management – from A to Z Our goal is to provide our customers with a full package service: not only the equipment, but complete support during each stage in the process to the final product.
D SIGN
What we mean by «die design» INJECTION LUBRICATION PARAM. Active Vacuum, Squeezing devices MATERIAL and DIE DESIGN COATING CHOICE THERMAL REGULATION
Design Our technical department in Sirone is composed by 24 technicians . We employ the latest versions of the most important software solutions, available on the market. CAM CAD
Part co-Design Working alongside the customer for the preliminary study of the die cast component, taking into account every single step of the manufacturing process: Make the die less complex and easier for the user to manage Optimize component’s features, helping to optimize cavity filling and minimizing porosity Improve casting trimming by working on the parting lines Enable easier component workability.
Simulation work – Castle by PiQ² Co.stamp employes a dual phase simulation software specifically developed for HPDC process. It is developed by company PiQ² in close cooperation with our R&D department. Starting from 2016 PiQ² is part of Co.stamp Group. - Bi-fasic Software (air-aluminum), based on open-source kernel (Open Foam) - Accurate calculation of air motion inside the cavity, flow pattern and effects of vacuum (see next slides) - User-friendly interface for die casting foundries Note: According to customer needs, we can run simulations with other softwares, available on the market (Magma, Flow3D, Procast), thanks to the good relationships we have established, during the years, with our suppliers.
Castle – some features High degree of accuracy in the determination of filling flow pattern. Vacuum 80 mbar No venting
Castle – some features Effect of venting on air flow pattern. Passive venting Vacuum 80 mbar
MANUFA TURING
Manufacturing of dies HPDC dies Type Aluminum Magnesium Alloy Automotive Industrial Market From 500t and up to 4500 t HPDC machines Size Powertrain Structural Application
Application areas: Automotive - Powertrain Gearbox housing Cylinder blocks Cylinder Head Flange housing Cover Steering housing Clutch housing
Application areas: Automotive - structural parts Instrument Panels Window Frames Bearing Flange Front Crossbeam Shock Towers Bearing Flange
Application areas: Automotive - trucks Transmission Housing Ladderframe Flywheel Housing Cover Cooling Duct Oil Pan
Workflow of the steel block c l d i a g h g f b e Assembly line g a d IN IN after HT h Die-tryout on HPDC presses b e Roughing & drilling Quality inspection of the steel i Quality inspection of the parts c f Semi-finishing and finishing stage OUT for HT l Machining of the parts
Manufacturing – Sirone shop floor Rough cutting and drilling
Manufacturing – Sirone shop floor Semi finishing and finishing
Manufacturing – Sirone shop floor Assembly room and hot spotting
Encoding system Implementing a codification system which assigns a barcode to each stage of the manufacturing process allows an accurate analysis of production progress for each single component, and related costs.
Maintenance & Refurbishment OUT IN Example 1 Example 2
TRY- UTS & SMALL PRODUCTIONS
Die Casting Foundry Co.stamp is equipped with an internal foundry department. Each die casting machine is placed in an automated workstation equipped with: casting extraction robot, automated lubrication system, cooling tank and trimming press. 3 Complete automated die casting Melting capacity workstations: 1 StrikoWestofen 2 StrikoWestofen ITALPRESSE 3000t TF Furnace Furnaces ITALPRESSE 2500t 500 kg / h 750 kg / h IDRA 1900t
Foundry Equipment Spray robot N°2 feeding lines Zone / Product 2-way and 4-way Vacuum system Blast furnace Foundry Equipment Extraction robot Thermal regulation Alloy treatment + degassing Jet cooling – 4 lines Squeeze Pin System Thermal regulation with electric system Quenching tank Casting integrity and cooling fixtures sensors Thermo camera Trimming
Die Casting Foundry Foundry Limited series (small batches) Special Al HPDC Productions dies tryouts Process development Special series Prototype series Aside a picture of one of our die casting workstation and an example of our special productions.
Case history of special series Lamborghini Huracan – Rear Grille Casting and trimming Dimensional check through dedicated fixtures and gauges Machining Teflon coating Delivery to customer for assembly
Case history of special series Lamborghini Huracan – Rear grille
Case history of special series BMW – C-Evolution Electric Scooter Casting and Trimming
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