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DESIGN FOR MANUFACTURE SPONSORED FEATURE


In many cases, ICEE uses cost-saving Solidworks 3D solid modelling to test and prove design for manufacture on-screen, but the company also makes physical prototypes


propagation leading to local or extensive weld breakage. This might lead to catastrophic failure of a chassis, hull structure or superstructure, a risk all designers and manufacturers will obviously want to eliminate. Thus, if a heat-based cutting process producing HAZ is used, oxide will have to be carefully and laboriously removed from cut edges before welding. This adds a costly operation and after fettling demands supervisory skills and more time to check results meet required standards. But there is a less costly and safer solution.


Waterjet, a cold-cutting process, solves the problem – no risky HAZ and no post- processing. It is ideal for aluminium, stainless steel and other ferrous and non-ferrous metals (and cutting plastics and composites). It results in a clean and accurate edge, and wastes little material as the kerf, or cut itself, is narrow. On thick plate, no wandering or ‘tapering’ of the cut occurs, so the edge is always square, regardless of material thickness. As the process is cold, a bonus is no risk of heat distortion or microscopic structural changes in the material.


VIRTUAL 3D PROTOTYPING So far, we have mainly looked at components. These may be part of a much bigger structure, or product, such as an electrical equipment cabinet, vending machine, automated locker system, or another type of standard or bespoke design. Besides parts manufacture, we specialise in


developing prototypes of the kinds of product cited above, leading to our subsequently making one-off, batch or higher volume production runs. We do a lot of this kind of business, sometimes working from a


customer’s sketch to design and make what is required, in other cases taking their drawings and specifications to update an existing range or develop a brand new product. Screen-based 3D modelling speeds up the


prototyping process and saves significant money (virtual iterations cost less), but sometimes also making a physical prototype is important. It brings a design out from a virtual concept into the real world. It sharpens understanding, forces a confrontation with reality and inspires new ideas. In some cases a physical model is the only way to fully ensure everything works properly. Effects like vibration, noise and hazard may be better judged. It is a double check on reality, you can ‘kick the tyres’. Again, working closely with customers, we


and they always learn a lot from this process (whether virtual or actual), especially where customers don’t have prototyping resources, or the highly advanced CNC machines we invest in. These include fibre-laser and waterjet cutting machines, brake press bending, punching and other fabrication and finishing equipment. This is all backed up by a high level of software ranging from 3D solid modelling to production optimisation packages. All these


resources are highly integrated so we can process a quote very quickly, simultaneously checking it through our software and suggesting ways to enhance the design. In conclusion, at ICEE we always advise


customers to talk to our design and manufacturing engineers at the earliest opportunity. It saves time and money and avoids those last-minute crises that may upset a vital product launch programme, or trigger a penalty for late delivery from your own customers. A few hours spent in discussion and seeing manufacturing processes at first hand is time well spent. Lastly, we also install, commission, maintain


and update many of the structures or products we manufacture for customers, so not only do we offer a complete, end-to-end service, but we also possess a considerable amount of knowledge and experience gained in these areas. In effect, we act as a trusted technical or collaborative partner on many key aspects of product design, development, manufacture and installation.


ICEE Managed Services T: 02392 230 604 sales@icee.co.uk www.icee.co.uk


Chris Arnold, ICEE Managed Services


“Screen-based 3D modelling speeds up the prototyping process and saves significant money (virtual iterations


cost less), but sometimes also making a physical prototype is important”


 DESIGN SOLUTIONS | MAY 2020 17


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