High quality RAPID PROTOTYPES to strengthen you in the best market position! A. A. MODELLERIA SINCE 1981 PROTOTYPING & MODELLING ENGLISH

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1 A. A. MODELLERIA FOUNDRY TOOLING AND RAPID PROTOTYPING SINCE 1981 ENGLISH SINCE 1981 PROTOTYPING & MODELLING 1 3D MODEL 2 LASER SINTERING 3 FOUNDRY TOOLING 4 CORES AND MOULD ASSEMBLING 5 POURING 6 FINAL PRODUCTS AS CAST OR MACHINED High quality RAPID PROTOTYPES to strengthen you in the best market position!

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3 ABOUT US P. 4 OUR TECHNOLOGY P. 7 3D design / CAD Pattern and Tool making Laser-Sintering and Mould making Pouring and Post-Processing Mechanical Processing Quality Management, Q-Control and Service OUR PRODUCTS, MATERIALS AND CLIENTS P. 30 LOCATIONS AND CONTACT P. 40 3

4 ABOUT US The A. A. Modelleria s.r.l. was founded on 19 December 2008 as the successor company of the Modelleria Angelino s.a.s.. With a 40-year history and our long-standing experienced staff, we are specialist in the field of models and molds for the foundry industry. We are Master in the field of foundry tooling manufacturing in wood, resin and metal using traditional and conventional technology, such as CAD, CNC, CAM and Rapid Prototyping. Thanks to in-house cutting-edge technologies, such as Laser- Sintering, we are able to offer the production of high quality and complex raw castings, machined parts or completed assemblies of Metal Casting Prototypes. 4

5 ABOUT US We can realize highest quality and complexity levels at extremely fast production time by using our special rapid prototyping manufacturing technology. Our customers are operative in all industries, worldwide. We have successfully carried out projects in the automotive, truck, rail, marine and industrial engineering fields, as well as in aerospace applications. We are an international team open to communicate directly with your team in English, German, Hindi and Chinese. FEEL FREE TO CONTACT US! 5

6 THE KEY TO SUCCESS IN YOUR HANDS! CAD PATTERN MOULD CORES MOULDING AND ASSEMBLY POURING AND POST- TREATMENT CASTING Q-CONTROL MACHINING MEASURING FINAL QC DELIVERY REALIZED IN AS SHORT AS 3 WEEKS! Lead time depends on difficulty, complexity, size, material and post-processing 6

7 3D DESIGN / CAD In our design department, our highly qualified staff will receive and evaluate your 2D and 3D data immediately after you will contact us. We promise to give you a feedback in the shortest time and will support your development engineers, if we identify design problems. A close cooperation with your team has our highest priority! WE ARE USING: CATIA V5 / ProE / UG / AUTOCAD / CAMTAGLIO / CAM TEBIS OUR SPECIAL SERVICES JUST ASK US! 3D design from scratch or basic 2D drawings Reverse Engineering using modern technologies such as optical scan and CT. 7

8 PATTERN AND TOOL MAKING In our pattern and tool shop, we can produce conventional patterns made of resin, wood and metal. Our staff members are highly experienced and masters in traditional techniques, but of course as well in the latest CNC technologies. On 11 modern machining centers, our experienced staff will realize your projects with the highest quality in a short time. CONVENTIONAL HANDCRAFT TRADITION What has been lost in many new companies, is still part of our excellence until today. Conventional pattern making directly from models, 2D, or you just give us a sketch. NO COMPUTER DATA BUT STILL HIGH QUALITY 8

9 PATTERNS AND TOOLS FOR YOUR SERIES PRODUCTION Besides the production of prototypes, we can offer complete ready-series solutions for gravity casting, permanent mold or low pressure casting. ASK US FOR DETAILS! Series complete tools for small, medium and large series Core boxes for conventional moulding and core shooting Wood / Resin / Metal / Light metals / Iron & Steel / Gravity / Permanent / Low pressure / Green sand / Cold-setting / Hot box / PERMANENT FOUNDRY TOOLING COMPLETE OF 5 CORE BOXES USED TO PRODUCE CYLINDER HEAD 9

10 PATTERNS AND TOOLS FOR YOUR SERIES PRODUCTION CYLINDER HEAD COVER FOUNDRY TOOLING COMPLETE OF 5 CORE BOXES WE SUPPLY FULL SERVICE! CONSULTING DEVELOPMENT RELEASE / OTS / INITIAL SAMPLES PROCESS PRE-SERIES AND SERIES RAMP UP REWORK / PROBLEM SOLVING ON-SITE SERVICE REQUALIFICATION 10 WE STAND AT YOUR SIDE UNTIL YOUR SERIES IS RUNNING AND.AFTER!

11 PATTERNS AND TOOLS FOR YOUR SERIES PRODUCTION WE CAN HELP YOU SATISFY YOUR CUSTOMERS! ENGINEERING OFFICES SERIES SUPPLIER TIER 1, 2, OEM INDUSTRIAL DESIGNER TOOL MAKER. UP TO THE ARTIST AUPPORTING ARM FOUNDRY TOOLING COMPLETE OF 3 CORE BOXES SEND US YOUR DATA AND REQUIREMENT AND WE WILL FIND YOUR SOLUTION! 11

12 PATTERNS AND TOOLS FOR YOUR SERIES PRODUCTION NO MATTER WHICH BUSINESS FIELD, WE ARE YOUR PARTNER! AUTOMOTIVE TRUCK & BUS HEAVY DUTY RAILWAY MARINE INDUSTRIAL AEROSPACE ENERGY GEAR BOX FOUNDRY TOOLING COMPLETE OF 3 CORE BOXES 12

13 LASER-SINTERING OF CORES AND MOULDS In today s global market, our customers face a tough competition. Only those who can develop rapidly and realize new products at the highest level play with the front. In order to strengthen our customers in the TOP league we have laid the basis for an extremely fast Prototyping QUICK CASTINGS by installing the laser-sintering technology for metal and sand, years ago. Today we have a great experience with this process and can realize a wide range of complex projects. LASER-SINTERING OF RESIN SAND 13

14 LASER-SINTERING OF CORES AND MOULDS During laser sintering, a mould segment or a core made of special resin bound sand is generated directly from 3D data. This eliminates the longer and expensive pattern or tool making and permits to realize otherwise not feasible designs. Especially for rapid developments and engineering loops it is easy to implement changes in a short time until your design works out. THE PROCESS OF SINTERING RESIN SAND LASER SINTERING GREEN MOULD/CORE BAKED MOULD/CORE 14

15 LASER-SINTERING OF CORES AND MOULDS GREEN MOULD/CORE 15

16 CONVENTIONAL MOULDING Besides the laser sintering, depending on the application, the A. A. Modelleria uses classical moulding methods. For example cold self-hardening resin bound mould materials. With our partners we can offer a variety of different systems, especially specific systems for aerospace castings are available as well. The combination with laser-sintering is the most convenient technology. FOUNDRY TOOLING COMPLETE OF 2 CORE BOXES CONVENTIONAL PATTERN WITH SINTERED CORES Using a well studied specific combination of different technologies, even the most complex designs can be realized at highest quality levels and in very short leadtimes. 16

17 EXTERNAL MOULD AND CORE TECHNOLOGIES In order to fully exploit any opportunity of complex core and molds requested by our potential customers (even the most unusual designs), we are able to make use of further highly modern technologies applied by our partners. One example is the use of external printed sand molds and cores. In addition, we can use shot cores for prototypes and small production batches. 17

18 LASER-SINTERING OF METAL POWDER Besides the laser sintering of special sand for castings, we offer direct metal sintering, to produce ready to use metal prototypes of steel and bronze. EXAMPLES SINTERING MACHINE FOR METALS 18

19 POURING AND POST-TREATMENT After the complete assembly of our moulds and cores the A. A. Modelleria has 2 strategies for the final casting. Besides prototypes we can offer small-, medium-and highvolume series to our customers. STRATEGY A «EXTERNAL POURING» In close cooperation and contractually secured, the A. A. Modelleria pours castings in external partnership foundries. Thus we can guarantee a fast and safe production of prototypes, as well as small to large volume series. The biggest advantage, is the wide range of available alloys and specific knowhow. We can realize light metals, heavy metals, steel & iron. We have tight confidentiality agreements to ensure absolute privacy for our customer s designs and our own staff attend and supervise the pouring process. 19

20 POURING AND POST-TREATMENT In order to be even more effective and faster in the future, especially for prototypes, the A. A. Modelleria is consistently extending its in-house pouring capabilities since STRATEGY B «INTERNAL POURING» With step by step extension of our own internal foundry, the quantity of prototype casting and small volume batches cast in-house will be higher and higher. In the first step we are installing melting and holding furnaces for aluminum and iron alloys. At the same time, in order to be able to offer our customers the complete package produced in-house, the capacity required for high-quality post-treatments is guaranteed. 20

21 POURING AND POST-TREATMENT For post-treatment of raw castings we use common industrial standardized technologies: UNPACKING AND DECORING WITH VIBRATION GRID CORE BREAKDOWN WITH HEAT TREATMENT - CORE GLOWING SHOT BLASTING OF RAW CASTINGS MANUAL FETTLING OF THE CASTING SURFACES, REMOVING CASTING SYSTEM ELEMENTS HEAT TREATMENT, STRAIGHTENING AND LEAKAGE TEST WELDING AND PRODUCTION WELDING IMPREGNATION PAINTING SPECIAL SURFACE TREATMENTS (E.G. ANODIZING, HARD ANODIZING, ) SPECIAL TECHNOLOGIES E.G. HIP 21

22 MACHINING To offer our customers the most out of one hand, we can finalize the finished castings with machining and also build up ready to use assemblies. With our 4 CNC machining centers and in close cooperation with highly efficient, specialized partners, we can offer our customers a complete mechanical machining processing as final step. Thus we are able to provide ready-made functional prototypes or complete assemblies in the shortest possible time. OUT OF ONE HAND 22

23 QUALITY-MANAGEMENT, Q-CONTROL AND SERVICE To ensure the highest raw casting and final part quality, we use the typical industrial standardized branch specific technologies. METALLURGY AND STRUCTURE SPECTROSCOPY MICROSCOPY AND MACROSCOPY ANALYSIS 23

24 QUALITY-MANAGEMENT, Q-CONTROL AND SERVICE X-RAY OF RAW CASTINGS RADIOGRAPHIC INSPECTION RADIOSCOPIC INSPECTION 24

25 QUALITY-MANAGEMENT, Q-CONTROL AND SERVICE MECHANICAL PROPERTIES HARDNESS TESTING HB TENSILE STRENGTH, ELONGATION, COMPRESSION 25

26 QUALITY-MANAGEMENT, Q-CONTROL AND SERVICE FURTHER INSPECTION Pressure tightness (leakage rate) at 1,5 bar (higher pressures with special equipment) Crack detection red/white, UV or magnetic detection In special cases CT with external partner 26

27 QUALITY-MANAGEMENT, Q-CONTROL AND SERVICE DIMENSIONAL INSPECTION One of the most important requirements for high quality castings, finished machined parts and assemblies is the compliance of dimensions and tolerances. The A. A. Modelleria has an index arm and a tactile coordinate measuring machine (CMM) to verify customer requirements. 27

28 QUALITY-MANAGEMENT, Q-CONTROL AND SERVICE EXTERNAL DIMENSIONAL INSPECTION Besides the classical tactile inspection we can offer the newest system for dimensional inspection, optical measurement using scanning technologies, in cooperation with an external partner. With this method we are able to do a complete inspection on raw castings as well as on ready machined parts and compare it to the nominal 3D data or 2D drawing requests. In this way it is possible too, to set up the raw castings in the best-fit position on the CNC machine to guarantee a good machining result for the first part! 28

29 QUALITY-MANAGEMENT, Q-CONTROL AND SERVICE In order to guarantee high quality and a stable quality management as well as traceability, the A. A. Modelleria has acquired the ISO 9001:2008 certification. 29

30 OUR PRODUCTS PATTERNS AND TOOLS FOR PROTOTYPES AND SMALL SERIES CYLINDER HEAD FOUNDRY TOOLING COMPLETE OF 8 CORE BOXES 30

31 OUR PRODUCTS PATTERNS AND TOOLS FOR PROTOTYPES AND SMALL SERIES MAIN HOUSING FOUNDRY TOOLING COMPLETE OF 26 CORE BOXES AND 12 LASER SINTERED PIPES MAIN GEAR BOX FOUNDRY TOOLING COMPLETE OF 46 CORE BOXES 31

32 OUR PRODUCTS RAW CASTING AND MACHINED PROTOTYPES, SMALL AND MEDIUM SERIES IN VARIOUS ALLOYS LIGHT METAL ALLOYS BRONZE 32

33 OUR PRODUCTS RAW CASTING AND MACHINED PROTOTYPES, SMALL AND MEDIUM SERIES IN VARIOUS ALLOYS IRON & STEEL 33

34 OUR PRODUCTS LASER-SINTERED METAL PROTOTYPES IN STEEL & BRONZE 34

35 OUR PRODUCTS LASER SINTERED CORES AND MOULD SEGMENTS AS SUPPLIED SERVICE Order your complex cores directly from us. We will supply your running production! 35

36 OUR MATERIALS EXAMPLES IRON & STEEL DENOMINATION WEIGHT MATERIAL 1) Crankcase Cursor Kg GJL250 2) Cover 80 Kg GJL250 3) Camshaft 43 Kg GJS500 4) Crankcase F1C 90 Kg GJL200 5) Cover 24 Kg GJL190 6) Exhaust Manifold 10 Kg SiMo RCT 7) Crankcase V6 100 Kg GJL200 8) Cylinder head 65 Kg GJL250 9) Crankcase Parkins 180 Kg GJL200 10) Support 7 Kg GJL200 11) Support 2 Kg GJL200 12) Pulley 4 Kg GJL200 13) Manifold 3 Kg GJS600 14) Water Manifold 4 Kg GJL200 15) Water Box 9 Kg GJS600 36

37 OUR MATERIALS EXAMPLES BRONZE & ALUMINIUM DENOMINATION WEIGHT MATERIAL 1) Pump 2 Kg Bronze B14 2) Manifold 2 Kg Bronze B14 3) Manifold 8 Kg Bronze B14 4) Manifold 3 Kg Bronze B14 5) Manifold 3 Kg Bronze B14 DENOMINATION WEIGHT MATERIAL 1) Primary Housing 24 Kg AlSi10Mg 2) Intake Manifold 9 Kg AlSi9Mg 3) Intake Manifold 2,5 Kg AlSi9Cu1 4) Intake Manifold 6 Kg AlSi7Mg 5) Gearbox 35 Kg A357 6) Cylinder head 10 Kg AlSi6Cu4 7) Cylinder head 15 Kg AlSi8Cu3 8) Intake Manifold 3 Kg AlSi9Mg 9) Vacuum Pump 10 Kg AlSi7Mg 10) Gearbox 6 Kg AlSi9Mg 11) Oil pan 4,5 Kg AlSi9Mg 12) Simens Cover 3,2 Kg AlSi7Mg 13) Gearbox 5 Kg AlSi9Mg 14) Cover 1,5 Kg AlSi9Mg You cannot find your alloy or you are not sure what is suitable for your product? Ask our specialists and we will support the selection of the best suitable alloy for your product! 37

38 OUR CLIENTS WE WERE ABLE TO SUPPORT AND SATISFY A GREAT RANGE OF WELL-KNOWN KEY CUSTOMERS IN THE LAST 30 YEARS WITH THEIR PROJECTS AND PRODUCTS YOU ARE INVITED TO BECOME OUR SATISFIED CUSTOMER! 38

39 OUR CLIENTS A. A. MODELLERIA S.R.L. VERTRIEBSOFFICE XLERATED A. A. MODELLERIA NORTH AMERICA INDAR MODELS PVT LTD. 39

40 LOCATION AND CONTACTS A. A. MODELLERIA S.R.L. Via Roma, Roletto (TO) ITALY Phone: Fax: WEB CEO Ing. Andrea ANGELINO SALES Mr. Michele MARANO QUALITY Ing. Rozela KROQI 40

41 LOCATION AND CONTACTS SALES AND TECHNOLOGY REPRESENTATIVE OFFICE INDIA Project and Sales Manager Mr. Jollyton D COSTA Mobile jdcosta@aamodelleria.com SALES AND TECHNOLOGY REPRESENTATIVE OFFICE GERMANY XLerated Accelerated Solutions Dipl. Ing. Mario SCHEIDLING Mobile +49 (0) vertrieb-de@aamodelleria.com A. A. MODELLERIA NORTH AMERICA Aspen Ridge Drive - Northville, MI USA Mr. Frederick SHEILL Mobile fsheill@aamodelleria.com 41

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44 OUR MOTTO HIGH QUALITY RAPID PROTOTYPES TO STRENGTHEN YOU IN THE BEST MARKET POSITION! THE CAPABILITY TO DEVELOP FASTER THAN YOUR COMPETITORS IS PROBABLY THE MOST IMPORTANT ADVANTAGE YOU CAN ACQUIRE ONE YEAR MARKET ADVANTAGE CAN EASILY AROUSE 20% COST SAVINGS KARL HEINZ BECKURTS ( ), GERMAN MANAGER