Precision Tooling Design & Manufacturing Lecture

Introduction

The Precision Tooling Technology Centre (PTTC) was founded in 1982 with a mission to transfer and disseminate advanced precision manufacturing technologies to the local mould and die industry as well as other manufacturing sectors.

The Centre is a pioneer in the introduction of various technologies to Hong Kong industry, including spark erosion and wire cutting, high speed machining, nano-machining and non-traditional manufacturing technologies such as micro fabrication and optical lens insert machining.

Precision Tooling Technology Centre

Objectives

Leveraging on its strengths in precision engineering technologies, PTTC aims to help and support local manufacturers to improve their competitiveness and increase the value-added content of their products or services.

Services

Product Design & Development

Industrial Design & Advanced 3D Mechanical Design

Industrial Design & Advanced 3D Mechanical Design
The PTTC provides a variety of design services including product drawings and 3D mechanical CAD/CAM models for precision tooling fabrication. It offers product development services such as the generation of viable mechanical design solutions from a preliminary concept.

Rapid Prototyping (RP)
The PTTC offers one-stop rapid product development solutions ranging from conceptual idea generation to the provision of detailed designs, and is capable of producing prototypes with precision ranging from 0.05mm to 0.20mm. The deliverables include physical conceptual models, functional prototypes, presentation models and CNC machined prototypes for pre-tooling design evaluation.

Rapid Tooling (RT)
When duplicate samples or prototypes are needed, Vacuum Casting Technique is used to duplicate samples based on PU material. These samples can be polished and painted, and are usually used as presentation functional models.

Precision Tooling Design & Fabrication

Tooling Design
Equipped with the latest advanced 3D CAD/CAM/CAE systems as well as technical expertise, the PTTC quickly deliver precision tooling designs with excellent quality.

Tooling Fabrication
Using Precision Engineering Technologies, tooling fabrication can be done quickly, while maintaining the quality and precision level. HKPC is experienced in the fabrication of a variety of moulds fabrication such as razors, razor covers, blade dispensers, swimming goggles, micro-motor rotors and end caps, optical lens, etc. A hot-runner system can also be applied to further improve efficiency.

Mould Trial & Pilot Production

Mould Trial
To guarantee the tooling quality, the PTTC carries out mould trials utilizing its in-house high precision Injection Moulding Machine. The moulded parts are sent to its Quality Control Section for verification, ensuring that the tooling conforms with the client's specifications.

Pilot Production
Prior to the client's commitment to multi-cavity and complex production tooling, the PTTC can fabricate a single-cavity pilot quick tooling for their review and evaluation of the product concepts. Normally, a quick tooling requires less time to complete and the cost will be justified if an expensive and complicated production tooling follows.

Precision Toolings & Quality Control

Quality Control Using Coordinate Measuring Machine (CMM)
CMMs are used for 3D measurement of profile dimension to ensure accuracy and tolerance.

Surface Profile Control Using Optical Projector
Larger 2D profiles are checked by a precision Optical Projector.

Laser Interferometer
The high frequency laser beam is used for non-contact profile measurement of float or spherical surfaces.

TaylSurf
This is used for contact measurement and advanced contour analysis of aspherical or conical surfaces.

Laser Welding for Mould Repairing

The mould and die making industry forms a core part of the local manufacturing industry. When a product design specification changes or a mould is damaged, it usually takes a long time for mould manufacturers to re-work or repair with the conventional argon welding approach.

To maintain the competitive advantage of the local mould and die manufacturing industry, HKPC introduces and promotes the laser welding technology. With the development of an integrated 3D automatic laser deposit welding system, HKPC assists the local industry to acquire the advanced technology in laser deposit welding for mould repair and mould design modification. In addition, it provides bureau and consultancy services to assist the local industry in the adoption of the developed technology.

With the Laser Deposit Welding System installed and integrated, the PTTC is capable of providing mould repair and modification services with high precision, low porosity and without thermal cracking.

The system is applicable to a variety of substrate materials including aluminum, copper and all conventional types of moulds and tool steels. By using the smallest laser spot (0.2mm in diameter) and wire (0.17mm in diameter), laser deposit welding can reach mould areas that a conventional welding method cannot reach.

Laser deposit welding technologies include: the development of an integrated CNC automatic 3D laser deposit welding system, development of a desktop CNC automatic 3D laser deposit welding system, and a manual laser deposit welding technology.

Micro-fabrication

Mankind is extending their engineering capabilities at both ends of the spectrum – from microscopic to macroscopic scales. In fact, the micrometer scale parts, no thicker than a human hair, have become very much a part of our daily lives, such as the micro-gear in watches, optical fibres that enable us to communicate over the Internet, and micro lens for information dissemination.

Silicon Micro-Electro-Mechanics (MEMS)
In nearby regions, micro-fabrication is focused on silicon-based technologies, which have matured but are still developing, to fabricate Integrated Circuits (ICs) for various applications. The Digital Mirror Device for digital projector is a typical example.

Non-Silicon Micro-Electro-Mechanics (MEMS)
As for non-silicon micro-fabrication, major applications in three sectors are now undergoing rapid growth, including optics, telecommunications and micro-medical devices. Competent in precision die and mould making and precision injection moulding in the region, Hong Kong's foundation industries have an edge over other competitors in the region in non-silicon micro-fabrication. They are experienced in the adoption of this new technology for the development of high value-added applications.

Real Time Computer-aided Production Management System for the Tooling Industry

Using a Real Time Computer-aided Production Management System to monitor the tooling production yields improved efficiency. This increases the flexibility of resources planning for a small batch production. The effectiveness of the improvement can also be measured.

The monitoring of both quantitative effectiveness (e.g. shop areas, inventory levels, working time, etc.) and qualitative effectiveness (e.g. information sharing, corporate dynamic, etc.) is enhanced. A shop floor data capture system utilizes barcodes and barcode scanners to accurately capture real-time data from fast moving shop floors. Data capture is faster and more accurate, while costs are lower and information can be retrieved in real time. The applications include:

Work-in-progress checking

Check of individual patched or work orders in any manufacturing process

Quality control

Automated quality control system
Statistical process control

Warehouse management

Pallet checking
Material in/out

Optics Development & Fabrication

The Optics and Opto-Mechatronics Technology Centre is the premier centre in optics design and manufacturing. It serves over 100 local companies in supporting their design and manufacturing of optical products, including digital cameras, film cameras, zoom cameras, binoculars, laser pointers, projectors and magnifiers. Our expertise and know-how have been enhanced through practical industrial projects and training as well as application development. The Centre offers consultancy services to the local industry in the areas of optical lens design, lens mould development, precision plastic lens injection moulding process, precision glass lens polishing and finishing, and lens inspection.

Facilities

CAD/CAM/CAE Systems

Alias | Wavefront
Unigraphics
ProE
CATIA
Solidworks
AutoCAD

Spark Erosion Machining (EDM)

Agie EloxMondo50
ActSpark SE1
Charmilles Roboform 22
Sarix SR-HPM micro EDM

Erosion Wire Cutting Machining

Charmilles Robofil 2030 TW
Charmilles Robofil 2000
Mitsubishi DWC90HA

CNC Lathe and Machining Centre

Hamai 5VA

High Speed Machining Centre

Mikron VCP 600
Makino V55

Precision Grinding (Optical Profile Grinding & Jig Grinding)

Mitsui Seki-3GB Jig Grinder
Waida PGX-3000 Profile Grinder

Coordinate Measuring Machine (CMM)

Ferranti Coordinate Measuring Machine (CMM)

Sub-micron Precision Measuring Equipment (Laser Interferometer & Talysurf)

The laser interferometer is designed to check optical surface quality and profile using non-contact interferometry technology.

The Form Talysurf can measure form, surface and contact types simultaneously for delicate surfaces. It can also measure and analyze aspherical or conical components.

Laser Deposit Welder

Integrated 3D CNC Laser Deposit Welding System

Injection Moulding Machines

Toshiba 1580G
Toshiba EC 100 2Y (Electrical)
Arburg 320C
Battenfeld TC40
Battenfeld Microsystem 50