Deep drawing in small series Creating value through smart engineering
Company profile Phoenix 3D Metaal specialises in 3D sheet metal forming in small series in Ferro and non-ferro metals. The company was founded in 1960 and is located in Eindhoven, The Netherlands. With over 50 years of experience manufacturing fine metal work, valuable product solutions in sheet metal have been achieved in various branches of the industry. By actively cooperating with TNO (the Dutch Organisation for Applied Scientific Research) and TU Delft University, specific expertise and capabilities in the field of metal forming with the rubber pad pressing technology are obtained. The company is Western-European leader in this particular method of production. Nowadays the company offers its partnership from the customer s initial product idea to serial production of the final product. The rubber pad forming technology 3D sheet metal forming in small series - the alternative technology for deep drawing The rubber pad forming technology is the cost effective alternative for deep drawing in small series. Complex double curved parts at low costs thanks to single-sided tooling is one of the main advantages of this technology. Well thought out product solutions enable the use of thinner sheet metal while maintaining product strength. Smart engineering enables manufacturing of costefficient and functional 3D sheet metal products, for example by including features such as reinforcements or embossments and by integrating functionalities. Phoenix 3D Metaal s core activities are: smart engineering, 3D sheet metal forming and 3D laser cutting, which are supported by additional processes such as (robot) bending and (robot) welding. Expertise in complex parts and specialised 3D laser cutting is essential and provides an advantage in realising double curved sheet metal products. With laser scan equipment, products are measured up to an accuracy of 0,05 mm. Laser scanning is applied for different purposes including quality control. It also enables reverse engineering and redesign of existing products/parts. Additionally, it offers the ability to provide measurement reports. The entire production process is supported by state-of-the-art CAD and CAM software. Simulation software was customised to meet the specific requirements of the rubber pad forming process and is crucial when designing complex shaped tooling and optimising product manufacturability.
Advantages Low tooling costs Particularly suitable for small to medium series production Freedom in design (double curved, organically shaped) Various materials: steel and stainless steel, several aluminium grades, brass, copper, zinc, wire mesh, titanium alloy and others on request Multiple smaller products can be formed from a single tool, in one run A single tool can be used to process various thicknesses of sheet metal Enables lightweight constructions and savings on raw materials Re-engineering of assemblies into one sheet metal product Short time to market Rubber pad prevents surface damages Fields of application The company produces custom made parts for equipment and machinery, covers and a variety of components. The applications are endless and Phoenix 3D Metaal serves various branches of industry such as Heating, Agriculture, Automotive, Food and Healthcare in which smart engineering leads to: Cost efficiency Hygienic, easy to clean and bacteria-tight products Lightweight product design, reducing product mass while maintaining strength Functionality by integrating product features, reducing weight and improving efficiency Flow improvement, optimising movement of gases and liquids
Rubber pad forming Process 2 1 3 Rubber pad Blank Die Blank positioned on die Pressing Semi-finished product 4 5 6 3D shaped sheet metal 3D laser cutting Product
Rubber pad forming Tooling Product design Die design Simulation
In summary Tooling costs are 5 to 10% of those of deep drawing tools Single tooling: short time to market Material thickness can be modified during process Smart product design: less components > minimise amount of welding seams Specialised in functional use of double curved sheet metal, enabling hygienic, lightweight and cost efficient product design Smart engineering leads to optimal product solutions > efficiency in material usage, product assembly and handling Phoenix 3D Metaal is partner from initial product idea and design to production and finishing of the product: one stop shop
Hygienic Hygienic product design Food industry No welding seams No residue
Lightweight Lightweight and strong through smart design Agro sector Less material Stronger product
Curved shapes and maintaining a lightweight product Automotive Freedom in design Organically shaped sheet metal
Identification in sheet metal with low tooling costs Façades and Signage Unmistakeable design Embossing Identity Functionality Integration leads to elimination Integrating product functionalities, reducing handling costs Automotive
From initial idea to optimal product design and finished end product or component Automotive One-Stop-Shop Smart engineering production finishing