Press Die Design

  • Cutting-, Fineblanking tools
  • Punching, Bending dies
  • Robotic line dies 
  • Deep drawing dies
  • Transfer-, progressive dies

Plastic Injection Mold Design

  • Injection molds, Overmolds
  • Cold runner-, Hot runner molds
  • Unscrewing-, Gearbox molds 
  • Compression-, Blow molds
  • Multi-shot-, Multi-component molds (2K, 3K…)

Other Engineering Services

  • Reverse Engineering
  • Product Development
  • JIG, Fixture Design
  • Product -, and process simulation
  • Sophisticated surface modeling

 

Our Design Process – Precision at the highest level

Each project is unique; therefore, our design process is scalable to any need and flexible enough to work with any size company. Our philosophy is we have one chance to get everything right in initial die design and engineering because changes past that point can be errors that cost time and money. And we approach every job with that same philosophy, whether it is a one-hole pierce die or a complex bodyside. When we design and engineer tools, we factor quality, efficiency and durability into the equation. We look at every detail to anticipate potential problems. Our years of experience allow us to enhance your tool to provide trouble-free operation and consistent performance. Our goal is first part that achieves 90% or better within specification. 

 

 

 

Fast and high-quality tool design in optimal size and minimum costs

Our designs are 100% 3D solid modeled using either die design software. We design to our customers’ standards and specifications in conjunction with our own internal processes and procedures to insure every design meets or exceeds our customers’ expectations. Our overall goal: give our customers the least number of operations that will produce dimensionally correct parts, based on their capabilities and equipment. We then perform finite element analysis of the tools and simulation to verify if the process is feasible for the part as it is designed.  We realize the value of using the latest technology available to create the best quality design possible. That’s why we leverage the leading, most up-to-date software in the tool & die and mechanical engineering industry for the services we provide. 

Cost-based Design for Manufacturability, Consulting

While die engineering and design may represent about 15 percent of the total cost of a die, it can impact 60 percent of the overall cost — particularly if it isn’t done right. A competitive product like vehicle must address factors such as cost, performance, aesthetics and quality. There are many process parameters which have great effect on the forming quality of B.I.W parts during automobile panel stamping. Proper method of Cost-based design can reduce scrap in manufacturing and Manufacturing Processes.

 

 

 

 

Sheet Metal Stamping Dies

 

Feasibility, strip layout design (method plan), optimization, simulation

The purpose of 2D Method Plan is to help customer understanding the die process more easily and facilitate better communication between two parties. We provide 2D format information with *.PDF file. The 3D method plan is provided with *.STEP format, which can be used for 3D die design and this result is served with springback analysis. In addition, it also calculates the right “forming force” and “binder force” with real draw bead modeling, and the process of analysis for spring back, “Compensation” helps us saving a time and cost to manufacturing actual tools. Our customers are therefore ensured of designs in-line with their budgets as well as a faultless, robust manufacturing and production processes.

  • 3D process design and simulation
  • Accurate blank and trim development
  • Material cost studies and Tonnage calculations
  • Progressive, transfer, tandem die process
  • Integrated ‘SpringBack’ compensation on surfaces

 

 

 

 

We routinely design large and complex line dies, transfer dies and stage tools for medium to highly complex parts

Line dies are used to manufacture large parts that cannot be efficiently manufactured in one press. We are capable of design high-quality dies that comply with our customers’ engineering specifications, standards and requirements. The production of large auto body panels requires very expensive tooling. We engage our customers in conversations of possible design improvements to the part so they can have the most robust manufacturing process possible. 

  • Bracket-type parts
  • Class A parts: body side panels, doors, hoods, roofs, fenders, etc.
  • Sophisticated, multicomponent projects
  • Dies for forming Advanced High Strength Steel, aluminum and exotic materials

 

 


 

 

Transfer-line simulation

UP Engineering’s transfer press simulation service provides key insights into your transfer die process before the dies are machined, built and tried out. Our service uses kinematics to check for crashes and close calls between the dies, transfer system and press. Your entire die is put into motion, including all pads, lifters, and cams, so full functionality can be verified. Full motion videos are included to clearly communicate any issues found in simulation. Curves can be easily adjusted and re-analyzed in minutes to optimize motions for the highest production rate. Once optimization is complete, upper and lower interference curves are generated for export to your design source. These findings allow you the opportunity to make changes and eliminate issues before the die is built; eliminating expensive and time-consuming fixes later in the build process. 

 

 

 

Plastic Injection Molds

 

Plastic injection mold and molding simulation

Complex and multi-cavity injection molds are designed by our engineers using various modules of plastics flow simulation software to simulate the filling, packing and cooling phases of the injection molding process and to predict the flow behavior of thermoplastic melts so that our customers can ensure parts of acceptable quality are manufactured efficiently.

  • Flow such as fountain flow, inertia effect and gravity effect
  • Pack; from material choices, gate designs and processing conditions
  • Cool; cooling channel layout and required cooling time in the design phase
  • Warp; part deforming ratio of shrinkage effect
  • MCM (multi-Component Molding)
  • RIM (Reaction Injection Molding)

 

 

 

 

From simple ‘open-close’ mold to highly complex production molds

From simple open-close single cavity prototype molds to very complex production molds with multiple actions. We are experienced with multiple styles of hot manifolds, 3 plate and conventional runner tools, insert molds and over molds as well as 2 shot and rotational molds.

Design activities are completed by a team of highly skilled professionals dedicated meeting customer standards related to the following markets:

  • Automotive parts
  • Electronic Connectors
  • Pharmaceutical / Medical parts
  • Aerospace parts
  • General Appliances

 

 

 

BIW, welding-, checking fixtures

 

 

We carry out designing tasks effectively and quickly be developing a new appliance

Body in White (B.I.W.) refers to the welded sheet metal components which form the vehicles structure to which the other components. Complete spectrum of body engineering services offer automotive body solutions that maintain regulatory compliance while utilizing alternative materials. Our capabilities span across BIW engineering, interiors & exteriors system, safety & restraints systems. We help shrink test and release timelines by adopting lab & field testing. 

  • 3D conceptual design
  • FEA structural optimization
  • Preparing of manufacturing documents

 

 

 

 

Related Engineering Services

 

 

Concept development

At the design stage of the project we create a prototype model in a virtual CAD/CAM/CAE environment. Concept design means exploring the possible implementation alternatives of the desired vision and the most appropriate selection process between them. The development is tailored to your requirements and will always reflect the state-of-the-art of development expertise and any development will benefit from our many years of experience in this industry.

3D-CAD design

Parts of the workpiece are constructed using parametric and direct editing using free form surface models, solid state models or hybrid models using the mixture of these two. Therefore you will benefit, perhaps sooner than expected, from opportunities to optimize details regarding issues of strength, weight and manufacturing. We also include in our design an adjustment of constructed space in as well as kinematic examination and models fully controllable by parameters.

FEA/CAE simulations

With the help of simulation, you can get an idea of the processes that are taking place during the initial phase of the product life cycle. You will have at your disposition valuable possibilities for maximizing improvements thanks to access to the most up-to-date FEA calculations as well as virtual simulations. This will provide you with a decisive edge in expertise which will benefit you during the development process.

CAM programming

With many years of experience and very varied projects, we know exactly which method is best for optimizing production processes. CAM is the acronym for computer aided machining. We use this technology to program tool paths for our CNC machines. This technology allows us to machine all types of complex surfaces that previously would have been machined manually or by hand. If it can be modelled on CAD then we can machine it with CAM.

CAD drawing creation

The closing phase of the design is the production of 2D production drawings before the production process, which require great attention and high precision. Our ready-to-manufacture drawings will provide you with details form shape and position tolerances, as well as surface finishing and information on the selected material. For purchase of commercial items and raw materials, a BOM (bill of materials) list is made of the plug-in components.

0 – series

Our powerful support doesn’t stop here, but we can support you at the post-development phase as well. When developing automotive units, there is a growing need for different pre-sets and prototypes. Based on the results of the simulations, we will choose the ideal manufacturing process for you, be it stereolithography, lasersintering, CNC milling, and many more. We help you shorten your development times, increase product quality and reduce costs.