COMPLEX PROTOTYPES AND SMALL SERIES Additive Processes // CNC & Casting // Machining // Coating & Finishing A A
CONTENT 03 WE ACHIEVE THE EXCEPTIONAL EVERY DAY // Alphaform was founded in 1996 as a specialist for additive manufacturing processes. Since then, we have become one of Europe's leading suppliers for prototyping and additive manufacturing, with over 200 employees at 5 locations. The name Alphaform stands for quality, capacity, reliable delivery and full service. 04 // WELCOME 06 // AUTOMOTIVE 08 // MEDICAL TECHNOLOGY 10 // INDUSTRY 12 // ARCHITECTURE, ART & DESIGN. 14 // CONSULTANCY AND SERVICE 20 // PROCESSES
04 WELCOME 05 WE ARE THE FIRST PLACE FOR YOU TO LOOK A WHEN YOU NEED RAPID RESULTS 100 true-to-size parts by next Tuesday? // There are only a few options in such cases. And Alphaform is one of them! We have one of the largest ranges of machinery and associated facilities and can except for highly specialised tasks carry out all work in-house. A WHEN YOUR SUCCESS DEPENDS ON IT Are mistakes out of the question? // Then Alphaform should be your first choice! Dedicated teams of experts will be responsible for your order at Alphaform, which will be co-ordinated via a computer-controlled project management process and monitored by strong quality assurance processes. The result is top-class manufacturing quality as well as absolute adherence to the content of your order and the promised delivery date. A WHEN DIFFICULT TECHNOLOGICAL PROCESSES ARE INVOLVED Maximum precision for complex components? // Alphaform can provide this. Our specialists have many years of experience and will support you in finding a solution to the most difficult of tasks. Our co-operation with the development departments of some of the leading technology groups in Europe shows that we are one of the first companies that others turn to as a problem-solving partner when constructing prototypes. A WHEN YOU WANT EVERYTHING TO COME FROM A SINGLE SOURCE Your prototype needs to be delivered so that it is ready to go on display? // You are in the right place at Alphaform. Top-class specialists will advise you along every step of the way. We work with the entire scope of professional manufacturing methods and operate a wide range of the best available machines. Everything is available from one source, including professional reworking and finishing.
06 OUR CORE AREAS 7 AUTOMOTIVE // Alphaform works for almost all the leading European automotive manufacturers and suppliers. The professional prototype buyers of the automotive industry are particularly drawn to our extensive expertise and high capacity. Alphaform distinguishes itself in this highly demanding high-tech sector due to its rapidness, quality and reliability. LAMBORGHINI Prototype development > Low-pressure injection moulding (RIM) PROTOTYPES PREPRODUCTION MODELS SMALL SERIES Preliminary designs and CAD data are made a reality thanks to our samples and prototypes. We manufacture and assemble preliminary design and functional models made from plastic, carbon and metal. One of our particular strengths is the bundling of manufacturing procedures for the production of complex components that require intricate processing steps. Examples here include AC systems, exhibition models, lamps, cockpits or door panels. No simulation can replace actual testing with the eventual original components. In digital manufacturing, we work with a wide spectrum of near-production materials in order to facilitate optimal functional tests. We also manufacture conventionally produced preproduction series in production mat erials in a reliable and quick manner. The differentiation with regard to production and equipment variants is growing steadily. This results in more and more vehicle components that are produced in very small quantities. Our expertise in working with small series allows us to produce competitive high-tech products in batches ranging from 1 to about 5,000 units.
08 OUR CORE AREAS 9 MEDICAL TECHNOLOGY // In medical technology, increasingly differentiated product portfolios are decreasing the quantities of each variant of a device that is produced. We offer comprehensive problemsolving expertise, from the prototype to the small series. Our production for medical technology is certified according to ISO EN 13485. This makes us one of the preferred development and manufacturing partners in the sector.»miro«medical ROBOT Design model development > Vacuum casting, colour-coated PROTOTYPES PREPRODUCTION MODELS SMALL SERIES Design and functional models serve, in particular, for checking the look-and-feel as well as the ease of use and operation of a device. We provide assistance as early as in the development phase when it comes to the selection of materials and moulds, which will subsequently enable cost-efficient production. Medical technology devices often have to pass through lengthy clinical test phases before they become widely available. During this period, they are only produced on an as-required basis and in the smallest of quantities. We deliver parts and components in a flexible, rapid and reliable manner, also in the smallest of batch sizes. Even after a successful market launch, component batches of between 1 and about 500 units per year are not uncommon in medical technology. We offer flexible production with short response times and in the quality appropriate for the medical technology sector.
10 OUR CORE AREAS 11 INDUSTRY // Regardless of whether our customers are looking for control panels, makeup containers or espresso machines we bring life to new industry designs. Our customer base of 2,500 customers from the consumer and investment goods industries value our comprehensive consultancy services and versatility when it comes to materials and manufacturing methods. HEAD SNOWBOARD BINDING Prototype development > Selective laser sintering PROTOTYPES PREPRODUCTION MODELS CUSTOMISATION The visual appearance, tactile qualities and function during prototype manufacturing are just as important as information concerning the expenditure for the subsequent series production. Our extensive experience allows us to provide you with precisely the prototype you need and to do so in a rapid, reliable manner in the desired precise design. Special machines that are only constructed in small quantities often require special plastic components as well. We produce these. Thanks to digital manufacturing, it is also possible to realise part geometries that are not possible with conventional manufacturing methods, such as injection moulding or thermoforming. Customised modifications of standard components are now economically feasible, particularly in the case of complex industrial goods that are produced only in very small batches. This applies, in particular, when digital manufacturing options are already being used. Customised products can help give your company the competitive edge by helping you stand out from the crowd.
12 OUR CORE AREAS 13 ARCHITECTURE, ART & DESIGN // We convert CAD data into three-dimensional objects of the highest quality. And we produce the smallest of production runs to meet the most exacting of demands. These capabilities make us ideally suited for the production of complex architectural models, copies of sculptures and highquality design objects. FRONT Design furniture development > Laser sintering ARCHITECTURAL MODELS SCULPTURES DESIGN OBJECTS We create detailed, expressive models in a single process step based on your CAD file. No limits are placed on the forming ideal for the perfect presentation of sophisticated preliminary designs. We can scan in three-dimensional models, such as sculptures, and reproduce them is almost any desired scale in various materials. This is of interest for copies of sculptures as well as the production of small batches of sculptures. Three-dimensional design objects, such as lamps or design-oriented everyday objects, can be realised via digital manufacturing methods without any tool-related design restrictions and in a wide range of materials. A new design flexibility, which, up to now, has been little exploited, is thus available.
14 CONSULTANCY AND SERVICE 15 SUPPORT FROM THE PROTOTYPE TO SMALL SERIES // There are dozens of options available for the production of prototypes, preproduction models and small series. We determine the best procedure, material and finish for you depending on your product and the product features that are most important to you. We will find the most suitable manufacturing solution for your challenge.. CONSULTANCY SERVICES Regardless of whether you are ordering your first prototypes or are highly specialised buyers and users: we can often provide you with valuable assistance when it comes to the design of prototypes and preproduction components, particularly with regard to the selection of materials and manufacturing methods. A A. ENGINEERING SERVICES We digitalise your design models by means of 3D scanners and support prototype modifications by means of reverse engineering. We design and modify part geometries and tools depending on the selected manufacturing methods. We provide support for small series in the form of design-to-manufacturing approaches.. TECHNICAL SERVICE We offer our customers full service for stereolithography systems, including system technology and optimisation, employee training, maintenance and raw material supply. We calibrate the laser, and optimise parameter settings and the focus. We improve process productivity due to our role as a beta tester for new software.
16 CONSULTANCY AND SERVICE 17 QUALITY ASSURANCE AND MATERIALS // Our testing and measuring facilities guarantee highest quality. Our quality management, which is certified according to DIN EN ISO 9001 and ISO EN 13485, ensures this at all times. INITIAL SAMPLE TESTS PROCESS CAPABILITIES SERIAL MEASUREMENTS Initial sample tests are drawn up according to current standards. Both tactile as well as visual tests can be carried out. The regular determination of the test equipment capabilities ensures the highest possible precision for your measurements. All systems and process steps are checked for their suitability as part of the process release. This is done by determining the statistical KPIs as well as via internal qualification and validation guidelines. Only then is a process released for series production. We ensure continuing process stability via a final inspection that is specially matched to each product. The type and scope of the test is defined based on customer and process requirements.
18 CONSULTANCY AND SERVICE 19 COMPARISON OVERVIEW Alphaform RP materials vs. production materials Material portfolio: STL/SLA/PolyJet methods COMPARISON OVERVIEW Alphaform RP materials vs. production materials Material portfolio: VAC/RIM methods 90 60 Zugfestigkeit in MPa / Tensile strength in MPa FullCure 850 PA 6.6 PA-Blends FullCure 720 Somos 7120 PP GF30 / PP TV 40 NanoTool 90 60 Zugfestigkeit in MPa / Tensile strength in MPa PX 223 PX 521 PA-Blends PX 226 PA 6.6 PX 245 PP GF30 / PP TV 40 30 Somos WaterClear Ultra Somos ABS 18120 Somos WaterShed XC Vero White Accura Xtreme Vero Grey Light Polyamid 2200 Somos 14120 DMX-SL 100 Somos NeXt PBT Somos 18420 Vero Grey Medium PP PE Vero Grey Dark Somos 15120 Somos ProtoCast AF 19122 ALU Polyamid 30 PE ABS PBT PP 3603/3905 Gummi FullCure 430 Somos 9420 Somos ULM 17220 Black Somos 10120 Alphaform Materialien / Alphaform materials Serienmaterialien / Production materials RIM 3602/3905 Tango Black Plus Shore A 95 Tango Black Plus Shore A 60 Tango Black Plus Shore A 27 Biegemodul in MPa Young's modulus in MPa AF V 150 Gummi AF V 100 Biegemodul in MPa Young's modulus in MPa 3000 6000 9000 3000 6000 9000 Alphaform Materialien / Alphaform materials Serienmaterialien / Production materials Alphaform Materialien / Alphaform materials Serienmaterialien / Production materials
20 PROCESSES 21 AUTOMOTIVE Development and production of a metal substitute (axle component) > Metalcoating TECHNICAL OPTIONS AVAILABLE TO YOU // We are proficient in a broad range of manufacturing processes for prototypes, preproduction and small series. Together with a range of materials unrivalled in Europe, this means that: Your order will be completed using the process and material that best suit your product. And in an optimal time frame. You get what you need, when you need it! Illustration: -Misha - Fotolia.com A METALCOATING provides small series and prototypes with new properties. Metalcoating adds a precisely defined, scalable coating of copper and nickel to plastic components. This metal coating has a homogeneous coating thickness in all areas, even in the case of complex geometries. This results in rapidly available, usable components with superior physical properties and a perfect metal look. Ideal for lightweight design Metalcoating provides components produced in this manner with a high and precisely scalable rigidity. The components can be produced in an extremely true-to-size, detailed and thin-gauge manner. They also allow for a high degree of freedom with regard to the design. This makes Metalcoating ideal for breakage and wear-resistant lightweight components that are required in very small batch sizes, such as in the aerospace or automotive industries. Special features The copper/nickel coating provides the components with additional properties that are important for numerous applications. The metal coating is resistant to wear and corrosion. It increases the temperature resistance and heat conductivity of the components, while the creep characteristics of the substrate are eliminated. The components are also electrically conductive, and housings made from metal-coated materials offer an effective EMC shielding. Perfect look and feel The even coating, with the nickel coating to the outside, provides the metal-coated components with a high-quality appearance. Polishing can give the coating a chrome gloss. For this reason, Metalcoating is often used in model construction in order to create perfect metal surfaces. Components with the Metalcoating also feel like metal objects with regard to both their tactile qualities and stability. This makes them highly suited for nearseries functional and test models.
22 PROCESSES 23 A STEREOLITHOGRAPHY (SLA) A computer-controlled laser cures fluid epoxy resin layer by layer. Alphaform uses 12 different materials in its 28 SLA systems, thus offering its customers a particularly wide application range. Stereolithography is particularly suitable for design models, data control models and functional prototypes. A REACTION INJECTION MOULDING (RIM) A milled mould made from plastic block material is used for RIM (which is also known as low-pressure injection moulding) for medium to large components. It is filled with liquid polyurethane, which subsequently hardens. This process can be used to produce small series of around 100 units in a cost-efficient manner. A SELECTIVE LASER SINTERING (SLS) In selective laser sintering, the workpiece is built up one layer at a time via powder application, followed by thermal fusing by means of a laser. This works with various materials, including polyamide and metals. This method is particularly suited for the production of functional prototypes due to the arising high strength of the workpieces. The process can also be used for the production of smaller series. A VACUUM CASTING & DIRECT TOOLING (STL SILICON) A master pattern is used as the positive mould for the production of a silicon mould. Using vacuum, liquid polyurethane is then filled in into the silicon mould, where it then hardens. The cast part can then be finished. Vacuum casting offers a quick, cost-efficient method for producing a small series from a master pattern. Moulds for flexible components can be created very quickly, even within one day, via the direct tooling, which has been further developed by Alphaform. A 3D PRINTING (POLYJET, VOXELJET) The PolyJet 3D printer creates a three-dimensional model by laying down successive layers of material. Workpiece sections can be created with various physical or tactile qualities due to the blending of two components. This allows for very smooth surfaces in the case of the PolyJet process, which makes it ideally suited for design studies. Nozzles incorporate a binder into the PMMA powder. It is possible to create both large components as well as lost models for sand and metal casting. A LAMINATION In lamination, fibreglass mats or carbon fibre mats are inserted into a one-sided mould, saturated with epoxy resin and cured. This traditional manual construction method is frequently used in the automotive sector for cockpit panels and dashboards as well as in racing, boatbuilding and sporting aircraft construction. It combines high strengths with comparably low weight. The lamination method is suitable when large functional models are required. A CNC MACHINING Workpieces that are produced via machining processes from massive blocks of production plastic or metal have the same properties as series-production parts made from the same material. For this reason, they are particularly suited for physical tests and have an excellent surface quality. We work with state-of-the-art 5-axis CNC machines that allow for many product shapes. A MODEL CONSTRUCTION Our model construction assembles modules consisting of parts produced by us and supplied individual parts. Conventional seriesproduction parts are frequently also installed. Some models consist of several hundred individual parts and are completed in time-critical processes. Our model construction also constructs, finishes and optimises the plastic tools that we use. A INJECTION MOULDING (PROTOTYPE AND SMALL SERIES INJECTION MOULDING) Prototype and small series (PK) injection moulding is the ideal solution when industrial plastics must be worked with due to cost or performance reasons. It differs from standard injection moulding only through the use of in-house CNC-milled aluminium moulds, which can be produced quickly, but do not have the same service life as conventional moulds. PK injection moulding is used for prototypes, preproduction series for test purposes as well as small series. A SURFACE TECHNOLOGY Perfectly formed surfaces bring the best out of a model. We have our own paint shop and are proficient in several coating methods for diverse visual appearances. Thanks to their expertise, our finishing department ensures the perfect end result.
We look forward to hearing from you! Alphaform Sales Fon +49 (0) 89 90 50 02-0 Fax +49 (0) 89 90 50 02-90 vertrieb@alphaform.de Alphaform AG Kapellenstraße 10 85622 Feldkirchen, Germany Phone +49 (0) 89 90 50 02-0 Fax +49 (0) 89 90 50 02-90 www.alphaform.de