Cases
Innovative Customer Solutions
You can count on the Flamborough Tool & Mould Ltd. team to use our experience, ingenuity and advanced machines to optimize your products and processes. The following cases illustrate some of our recent innovations.
[Case 1]
We're the “Go To” sub-contractor for highly efficient precision work
Independent, cost-effective and technically skilled, Flamborough Tool & Mould Ltd. was the sub-contractor of choice when this large automotive die cast specialist needed to manufacture a highly complex valve body. The manufacturer got top quality and the contractor still had margin on the product.
We handled all aspects of the design and manufacturing process for the creation of a complex valve body.
[Case 2]
We quickly reverse-engineered & ran simulations to optimize part
Flamborough Tool & Mould Ltd. was hired to improve the flow of aluminum to a fill cavity. In less than one week, we re-engineered the gate working from the original tool, ran simulations and re-engineered it for optimized flow.
See optimized flow (video clip).
This was a problem-solved for our customer. And it’s a capability built into our standard mould service. Before cutting any steel we run simulations so we can build moulds right the first time. And that’s just one example of how we add-value and deliver more than you’d expect from a small shop.
[Case 3]
We re-engineered a 4-cavity mould and reduced costs by over 50%
Flamborough Tool & Mould Ltd. re-engineered a 4-cavity mould replacing hydraulic cylinders with CAMs. This change:
- improved functionality, enabling greater travel limits
- increased the cleanliness of operations
- removed maintenance issues and increased part reliability
- reduced set-up costs by over 50%
[Case 4]
We extended the working life of a dip stick core coating by 75%
Before our work, this dip stick core for an oil pan coating was lasting only a week before it started to solder. After Flamborough Tool & Mould Ltd. solved the problem, the coating lasted a full four weeks, netting significant cost and time savings.
[Case 5]
Our Makino machining leaves no white layer & saves customers money
Flamborough Tool & Mould Ltd. was an early adopter of machining to cut hardened steel rather than using the Sink EDM process. For the last 5 years—long before many other manufacturers and mills—we’ve offered this large shop capability with small shop pricing.
We cut your steel once, at half the cost of making electrodes and burning steel. And avoiding the white layer formation from sink EDM extends the longevity of the part which saves our customers even more money.
Creativity & Continuous Improvement
We’re never satisfied. Even when our precision products are considered among the best in the world. We’re always looking for ways to make the product better, the process faster, the part more robust or long-lasting. Here are some examples of our approach:
[Case 6]
We optimized the process to manufacture valve body ejector pin holes
Using proprietary processes and tools and creativity, Flamborough Tool & Mould Ltd. set out to improve the precision, cost and speed of aligning ejector pin holes. We achieved it without having to grind the holes, wire or bore them. What’s more, our new process is doable even with exotic metals.
[Case 7]
We slashed the time needed for the assembly of a die cast machine shot arm to only 5 minutes!
Replacing worn parts and dealing with broken bolts produced down time and many hours of manual labour for our customer. We knew there had to be a better way. So we applied Flamborough Tool & Mould Ltd. ingenuity and created a new, quick change assembly carriage system. The total time for assembly went from 120 to 5 minutes.
Sorry, no picture since this is a proprietary solution.
Just imagine what challenges we can solve for you!