Deep drawing in small series

Creating value through smart engineering

Company profile

Phoenix 3D Metaal specialises in 3D sheet metal forming in small series in Ferro and non-Ferro metals. The company was founded in 1960 and is located in

Eindhoven, The Netherlands. With over 50 years of experience manufacturing fine metal work, valuable product solutions in sheet metal have been achieved in

various branches of the industry. By actively cooperating with TNO (the Dutch Organisation for Applied Scientific Research) and TU Delft University, specific

expertise and capabilities in the field of metal forming with the rubber pad pressing technology are obtained. The company is Western-European leader in this

particular method of production. Nowadays the company offers its partnership from the customer’s initial product idea to serial production of the final product.

The rubber pad forming technology

3D sheet metal forming in small series - the alternative technology for deep drawing

The rubber pad forming technology is the cost effective alternative for deep drawing in small series. Complex double curved parts at low costs thanks to

single-sided tooling is one of the main advantages of this technology.

Well thought out product solutions enable the use of thinner sheet metal while maintaining product strength. Smart engineering enables manufacturing of cost-

efficient and functional 3D sheet metal products, for example by including features such as reinforcements or embossments and by integrating functionalities.

Phoenix 3D Metaal’s core activities are: smart engineering, 3D sheet metal forming and 3D laser cutting, which are supported by additional processes such as

(robot) bending and (robot) welding. Expertise in complex parts and specialised 3D laser cutting is essential and provides an advantage in realising double curved

sheet metal products. With laser scan equipment, products are measured up to an accuracy of 0,05 mm. Laser scanning is applied for different purposes including

quality control. It also enables reverse engineering and redesign of existing products/parts. Additionally, it offers the ability to provide measurement reports.

The entire production process is supported by state-of-the-art CAD and CAM software. Simulation software was customised to meet the specific requirements

of the rubber pad forming process and is crucial when designing complex shaped tooling and optimising product manufacturability.

Advantages

Low tooling costs

Particularly suitable for small to medium series production

Freedom in design (double curved, organically shaped)

Various materials: steel and stainless steel, several aluminium grades, brass, copper, zinc, wire mesh, titanium alloy and others on request

Multiple smaller products can be formed from a single tool, in one run

A single tool can be used to process various thicknesses of sheet metal

Enables lightweight constructions and savings on raw materials

Re-engineering of assemblies into ‘one’ sheet metal product

Short time to market

Rubber pad prevents surface damages

Fields of application

The company produces custom made parts for equipment and machinery, covers and a variety of components. The applications are endless and Phoenix 3D Metaal serves various branches of industry such as Heating, Agriculture, Automotive, Food and Healthcare in which smart engineering leads to:

Cost efficiency

Hygienic, easy to clean and bacteria-tight products

Lightweight product design, reducing product mass while maintaining strength

Functionality by integrating product features, reducing weight and improving efficiency

Flow improvement, optimising movement of gases and liquids

Rubber pad forming – Process

Blank positioned on die

Rubber pad

Die Blank

Pressing Semi-finished product

3D shaped sheet metal Product 3D laser cutting

2 1 3

4 5 6

Rubber pad forming – Tooling

Product design Die design Simulation

Rubber pad forming – Positive / negative pressing

Positive pressing Negative pressing Combination positive/negative • Similar to bending

• Relatively simple die

• 3D laser cutting not always

necessary

• Good process control

• Complex die

• Demanding shapes are possible

• Similar to deep drawing

• Process control

• Complex die

In summary

• Tooling costs are 5 to 10% of those of deep drawing tools

• Single tooling: short time to market

• Material thickness can be modified during process

• Smart product design: less components > minimise amount of welding seams

• Specialised in functional use of double curved sheet metal, enabling hygienic, lightweight and cost efficient product design

• Smart engineering leads to optimal product solutions > efficiency in material usage, product assembly and handling

• Phoenix 3D Metaal is partner from initial product idea and design to production and finishing of the product: one stop shop

Hygienic No welding seams – No residue

Hygienic product design – Food industry

Lightweight Less material – Stronger product

Lightweight and strong through smart design – Agro sector

Exceptional Product identity – Outstanding

Sheet metal in distinctive design and demanding environment – Construction

Freedom in design Organically shaped sheet metal

Curved shapes and maintaining a lightweight product – Automotive

Unmistakeable design Embossing – Identity

Identification in sheet metal with low tooling costs – Façades and Signage

Functionality Integration leads to elimination

Integrating product functionalities, reducing handling costs – Automotive

One-Stop-Shop Smart engineering – production – finishing

From initial idea to optimal product design and finished end product or component – Automotive

Flow Reduce resistance – Improve movement

Automotive specials Heating industry