SERVICES

Design

Product Engineering
The original Customer model is elaborated in order to optimize it for the chosen plastic material and production process; limits and technological, aesthetic as well as economical restraints of the solution are also defined. This takes place in close cooperation with the Customer and the internal production departments.

Mould Design and Construction
Following the phase of Product Engineering, design begins on the mould and any auxiliary equipment aiming at the realization and control of the required product.

Process Engineering
Thanks to the use of the process simulation CAE program Moldex3D, Cattini is able to estimate very accurately and at an early stage of the project which will be the mechanical, aesthetic and dimensional features of the finished product.

Tool Construction

Moulds for Injection Moulding
Moulds are made both internally and externally, anyway, always on the base of our specification.
Internally: in case of reduced delivery times or prototype moulds needing fast and repeated working out.
Externally: when the delivery date allows it or when the mould dimensions and machining are prohibitive for our machines; in this case suppliers are followed by our specialized technical staff and realize the equipment on the basis of our technical specifications.

Auxiliary Equipment
Equipment necessary for the production process, such as:
- equipment for automatic parts drawing,
- sonotrodes and laying devices for US welding,
- equipment for mechanical tests,
- equipment for dimensional check.

Sampling

The purpose of sampling is to:

Check that the mould, entirely inspected, realizes the required part correctly, using specific devices, requested by the customer, for the necessary dimensional check, as well as coordinate measuring machines, vision measuring machines and traditional bench instruments;

Define the process parameters and capability for subsequent production; on the base of modern, constantly maintained machines, we can define the process capability for new products, using SPC (Statistical Process Control) techniques and hence ensuring a constant quality standard for all the following supplies;

Determine the technological limits of the production process

Qualify the product, by using appropriate measuring devices, in order to obtain the Customer's approval and freeze the production process. The entire sampling phase is followed by qualified personnel in continuous cooperation with the Customer; at the end of this phase and in case of successful outcome, all the necessary data are recorded for creating the specific Operating Instructions which are essential for implementing the subsequent production.

Production

Pre-moulding treatment
Through the use of different equipment (air exchanger driers, dehumidifiers) raw materials become free from residual moisture and the process stability is guaranteed thanks to a periodical check assuring that materials are complying with manufacturer's specifications.

Injection moulding:
Injection moulding can count on modern machines, customized with the integration of the auxiliary equipment control and subjected to a constant maintenance program. The machines are equipped with a software that allows statistical process control (SPC), ensuring the greatest process stability.

Assembly
The company is so structured that it is able to assemble parts, by using different types of equipment, among which the US welding.

Quality

Testing
Quality control has traditional type bench instruments and modern measuring devices such as coordinate measuring machines and vision measuring machines. Thanks to them and to the specialization of our engineers we are able to periodically check the critical dimensions of each part. On request, capability studies (Cp - Cpk) can be performed thanks to SPC (Statistical Process Control) techniques. Parts can also be compared to mathematical models through the use of measurement software. We have dedicated equipment for checking U.S. welding through peel tests, both extended and strained. In addition, we are able to carry out moisture analysis of the polymeric raw material and of the moulded parts (Sartorius MA100 moisture analyser), as well as to check the specific weight (Sartorius ME254 S electronic analytical weighing machine), both on the raw material and on the finished parts. If more in-depth investigations are necessary, we cooperate with external designated laboratories specialized in specific tests on plastic, such as DSC, viscosity measurement in solution, TGA, Melt Flow Index and so on.

Quality Assurance
Our Company Quality System is certified according to the UNI EN ISO 9001 and UNI EN ISO 14001 standards by TUV SUD.
We are also accredited for the production of items intended for the food industry, in compliance with EC Regulation 1935/2004 (MOCA).

Monitoring
As an additional controlling tool, Cattini has adopted cavity pressure sensors, choosing Kistler products. Thanks to CoMo Injection unit, these sensors detect the correct pressure in the cavity and allow, in case of problems, to isolate the single beat, in order to ensure a more stable process and a better quality.
Once the ideal pressure curve is defined, it is possible to correlate the findings to the part's dimensions and thus be certain that, if the curve is repeated, the parts are uniform.
As to production flexibility, in addition, this information is very useful when the mould is transferred to a different moulding machine. Once the curve is defined, it is sufficient to repeat it on different machines to achieve the same dimensional results.

Tools and equipment maintenance

Maintenance is a company procedure, aiming at carrying out a prior intervention, so that the likelihood of failure and/or degradation of a production unity operation is reduced. Maintenance is managed by a specific scheduler software that part-time alerts the tooling staff.
Our tools and equipment are covered by All risks insurance.

Heat Treatments (Post-curing)

Our company has a battery of Votsch and Heraeus ovens, aimed at performing the post-curing treatments which are necessary for Torlon (PAI) imidization. Ovens are used also for the treatment of carbon charged PEEK.

POST CURE
The parts obtained from the injection molding of Torlon (PAI) must undergo a thermal process known as POST CURING. This step is necessary to achieve the properties listed in the Torlon PAI Design Manual of Solvayplastics. Uncured or inadequately cured parts will not perform at the expected levels. The post cure process consists in placing moulded parts in fan ovens and thermally treating them, by increasing the temperature at different intervals. The standard cure cycle is suitable for parts with a maximum cross-sectional thickness of 7.6 mm (0.3 inch). Cattini can determine the best post cure schedule for any application and check that moulded parts are fully cured.