PRECISION & SPEED: THE CAVALIER WAY
“The cost per part for the molder is the most important thing,” says Cavalier Sales Manager Tim Galbraith. “So, our job is to take the cycle time out of the tool. We help customers produce parts much faster and at a lower cost than their competitors.”
7-Gallon Tote Project:
Much complexity goes into a mold – and on a recent project required a multi-cavity mold to efficiently produce a large volume of 7-gallon totes, we tasked our design and manufacturing teams to solve some unique problems that the customer requirements presented.
The results speak for themselves.
Utilizing Industry 4.0 tools like mold filling and cooling analysis, we were able to optimize gate location and cooling. Finite element analysis of the tool construction to optimize locks and steel sizes; in press simulation allowed optimization of the demolding and end of arm tooling configuration. All completed prior to beginning of the manufacturing process.
By doing all of this at the design stage, there’s no guesswork. The length of rubber and braided hoses, all bracketry and fittings, even wiring and wire clips are included in the design. This allows everything to be manufactured and prior to assembly minimizing toolmaking time. “It also makes for a good-looking tool,” says Galbraith.
One example: the location where the injection points are normally on the bottom but on this job it’s on the side so the flow is shorter. The result: faster fill with less tonnage required.
There is also a phenomenal amount of cooling we were able to put into this tool to lower the cycle time.
“Everything is well organized and well thought out. It’s serviceable, and it looks good,” says Galbraith.
The Cavalier Way.
“Our way involves extensive design time and may involve many iterations. Extensive reviews are often required to optimize filling and cooling of the tool. Consideration to access of all hydraulic hookups and water lines is all part of the process.
“Everything has to be accessible and that is what our design team does so well. It is well thought out, well designed and well, it just happens to look great too. “
And speed? Cycle time is king in a high production environment.. In few areas, we may use copper alloys as we did with this part. While the material cost is about 20 times the cost of steel, the thermal conductivity is more than 10 times that of steel making it a cost-effective option.
If we can cool it faster, we have even greater success cutting cycle times.
If we can get twice as many parts per minute – and the tool cost is more, the end result leads to significant cost savings to the customer.
In the end our customers aren’t buying a tool – they are buying a result.
While offshore suppliers may be able to make the tools cheaper, they don’t produce the results we do. They just won’t run as fast.
Our customers tell us that the cycle time we save them more than makes up for the higher cost of the tool.
And we don’t skimp on testing either. A program manager does a complete end to end test during at tryout at a local shop.
Everything must be balanced – fill, cool and demolding to make the tool production ready.
Precision is key when we build the tool.