The challenge

Industrial automation is more than just automating existing processes with standard components. Demcon Industrial Systems also develops new, high-quality production technology for the manufacturing industry, such as the Fleximould. The manufacture of moulds is time-consuming and expensive, certainly for small series production. A solution lies in a mould that is easy to reconfigure for subsequent products. Fleximould is such a reconfigurable mould that can be used, for instance, for relatively fast and inexpensive thermoforming of plastic products of a complex design.

The solution

Fleximould is a ‘pin bed’ in which pins are wedged next to each other and are height adjustable to 0.1 millimetre precision. DIS is working together with the Hochschule Niederrhein in Krefeld (D) in the ‘Smart production’ Interreg project on the further development of the concept for industrial application. The mould used for research in Krefeld has 30,000 pins of 6 millimetres in diameter and 300 mm in length in a 1,600 by 600 millimetre bed. The most important development challenges were ensuring that the mould is vacuum tight (for thermoforming) and the configuration of the mould.

To position the pins, the software translates the 3D CAD drawing of a product into height coordinates for the individual pins. Pneumatical actuators beneath the mould ‘re-set’ the mould, so that all the pins can be configured in batches to the highest position. The linear electric actuators above the mould then push the pins downwards one by one, until they are at the desired height.  They are kept in place by clamping them by friction in the right position.

For a large mould this takes several hours because of the large number of pins and the required precision; this is precision positioning on industrial scale. Demcon Industrial Systems is the designated specialist for this, supported by all the Demcon group’s mechatronic competences.

The Smart Production project is part of the INTERREG program Germany-Nederland, co-financed with funds from the European Fund for Regional Development (EFRE), the Ministry of Economy, Energy, Industry, Small and Medium-Sized Enterprises of the State of North Rhine-Westphalia (MWEIMH NRW), and the Ministerie van Economische Zaken, as well as the provinces of Fryslân, Gelderland and Overijssel.

Informationsheet Fleximould
Funded as part of the INTERREG “Smart Production” project.

Main characteristics

  • Flexible mould system
  • Serves various applications that need free-form shapes
  • Pin diameter Ø6mm
  • Mould size and setting speed adjustable