Problem solving and development of a new product range
The product was originally manufactured with a metal frame for the needles. The analyses and calculations proved that a plastic material with a special structure and strength can offer a significantly better lifetime. At the same time, the manufacturing costs have decreased considerably. The comb can not only be used in the intended medium load zone, but is also perfectly suitable for the heavy load zone.
Verification of the load limits of the needle comb with FEM simulation
Concept of a completely new manufacturing approach. Design with simulation of the load and optimisation of the design for injection moulding. Validation of the sample series. Delivery of the moulds.
Test and quality assurance
Verification of results with final fracture tests
The theoretical results were validated and qualified with injection moulding tests and subsequent fracture tests. The manufacturing processes were clearly described and handed over to the customer with working instructions. This makes production reproducible for the company. The know-how transfer is completed with the handover of the documentation.
Simulation of the flow front temperature during the injection moulding process
The customer has not only received an improved product. The know-how transfer has given the company advantages on the market beyond the product itself. The customers benefited was far beyond the production of the needle comb.