MODELLERIA
ZUIN
WE OFFER HI-TECH INSTRUMENTS AND SOLUTIONS TO REALIZE PROJECTS… NEVER SEEN BEFORE
KNOW HOW TEAM
MODELLERIA
ZUIN ENGINEERING AND RAPID PROTOTYPING SERVICES TO SPEED UP THE TIME TO MARKET Specialized
in
the
construction
of
casting
complete
equipment, Modelleria Zuin always works according to the highest quality standards, thus being able to supply tools realized with the best materials in a very short time and with those skills developed after a long-lasting cooperation with the
OLTRE PROTOTIPO E DALL’IDEA AL
most
important
Italian
and
European
customers.
Equipped with one of the widest machine fleet, the
DALL’IDEA AL PROTOTIPO E OLTRE
company offers milling and prototyping solutions, together with a considerable design support.
CNC CONSTRUCTIONS FROM SOLID MATERIAL / MECHANICAL MACHINING
PRE-PRODUCTION SERIES SUPPLY
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Page 4 SCANNING AND REVERSE ENGINEERING
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FOUNDRY EQUIPMENT CONSTRUCTION
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3D DESIGN
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PROTOTYPE CORES FOR FOUNDRY
Page 6 RAPID PROTOTYPING WITH METALS FOR DIGITAL PRECISION CASTING RAPID PROTOTYPING WITH METALS FOR “QUICK SAND CASTING”
DIRECT METAL LASER SINTERING (DMLS)
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Page 7 PLASTIC AND RUBBER RAPID PROTOTYPING
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CARBON FIBER LAMINATION PROTOTYPES
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KNOW HOW TEAM
MODELLERIA
3D DESIGN
ZUIN
3D MODELING, CO-DESIGN AND INDUSTRIALIZATION 3D DESIGN - No. 9 CAD workstations for solid or surface modeling
Thanks to many different CAD workstations, equipped with state-of-the-art 3D software, we can perform 3D surface and solid modeling.
Our long-time experience, due to the cooperation with the most renown companies operating in the mechanical technology field, allows us to face even the most complex projects easily, such as differential gears, gearboxes or heads for engines.
We can develop the creative ideas of our customers just starting from simple sketches and engineering dimensions, kinematic motions and all the other main aspects of design. We make structural calculations, FEM analysis, fluid mechanics simulations and simulations of casting/filling.
“IDEAS AND SOLUTIONS TO MAKE THE DIFFERENCE”
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3D SCANNING & REVERSE ENGINEERING
MODELLERIA
ZUIN
3D RECONSTRUCTIONS SCANNING AND REVERSE ENGINEERING - Laser, structured light or contact scanners. Measuring range from 45mm to 45m, with measuring precision from 0,01 to 0,1mm
Equipped with different 3D scanners, we can “digitalize” physical objects and transform them into CAD projects, which are also editable thanks to parametric remodeling.
AT THE SERVICE OF VINTAGE CARS These technologies are perfect for the reconstruction of improved spare parts for vintage cars or vintage vehicles in general, in particular for those cars running high-performing races, and whose availability or price has become an obstacle difficult to overcome.
DIMENSIONAL INSPECTIONS We can perform measurements and 3D reconstructions also in order to check those deformations caused by production processes or worn equipment.
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CNC CONSTRUCTIONS AND MACHINING
MODELLERIA
ZUIN
3 AND 5-AXIS CNC MILLING MACHINES CNC CONSTRUCTIONS FROM SOLID MATERIAL/ MECHANICAL MACHINING - 3, 4 and 5-axis high-speed CNC machines with working range up to 3000mm. Workings carried out on every kind of material, from resins to heat-treated steels The machine fleet includes many 3 and 5-axis high-speed milling machines, with a working range up to 3000x1000x800mm. They are ideal to work any type of material, such as plastic resins, aluminum, steel, titanium, etc. We build foundry patterns and core boxes, and precision casting molds, dies and equipment. In particular we realize special equipment for the hydraulic sector.
CNC PROTOTYPE CONSTRUCTION We can realize prototypes obtained directly from a solid material block (ideal to get extremely refined objects such as Plexiglas lenses for lights, or elements made of alloys like Avional速 or Inconel速), or perform CNC machining of cast elements.
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SERIES AND FOUNDRY EQUIPMENT QUALITY CONTROLS
KNOW HOW TEAM
MODELLERIA
ZUIN
SERIES AND FOUNDRY EQUIPMENT PRE-PRODUCTION SERIES SUPPLY - Plastic or rubber molded parts; supply of aluminum, cast iron or steel castings.
By combining the analysis and CAD modeling skills with the resources given by CNC milling machines, Modelleria Zuin is able to develop foundry equipment
also for the serial
production of metal castings or plastic and rubber elements as well. Using our industrialization ability, where necessary, we can also carry out technical/economical analyses to limit the industrial production costs.
QUALITY CONTROLS We can carry out a wide range of tests, in order to trace and certify the features of the mechanical prototypes or of the pre-production elements (for validation purposes). We make both non-destructive (hardness, continuous radioscopy, radiography, 3D measurement, penetrant inspection) and destructive controls (micrography, spectrography, traction). Radioscopy (for light
CONTINUOUS RADIOSCOPY SYSTEM
alloy parts) or radiography (for ferrous alloy parts) tests are particularly appreciated as they allow the localization of the inner defects of components, such as solidification or shrinkage problems.
CTR 3D
RADIOSCOPY
RADIOGRAPHY
The most accurate control is the so-called Computed Axial Tomography, or CAT, which allows the detection of surface and defect dimensions all in one go, thus permitting the identification of defect size and exact 3D position. 3D CAT allows also the scanning of functional cavities, like water and oil circuits, or other spaces which can’t be checked from outside.
3D CAT
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MODELLERIA
KNOW HOW TEAM
PROTOTYPE CORES
ZUIN
PRINTING BECOMES DIGITAL PROCESS SERVIZI DI INGEGNERIA E CORE DI PROTOTIPAZIONE RAPIDA A PER ACCELERARE LO SVILUPPO DI MERCATO PROTOTYPE CORES FOR FOUNDRY - No. 4 3D printers with working range up to 1800 mm and prototype cold box process and No. 2 sintering systems with a working range from 750mm and prototype shell-molding process
The most modern 3D printing systems can perform prototype cores which are to be used in pre-production tests. We are able to print cores that reproduce the two most common industrial production processes through the following techniques: • Prototype cold box (cold polymerization) • Prototype shell-molding (hot polymerization, sintering) The cores obtained from prototype shell-molding are ideal to realize small and complex casting cavities, where the highest resistance and the best precision in details is required. The cores obtained from prototype cold box, thanks to their high dimensional stability (printing without post-process) are perfect for those objects with middle-big dimensions or where the maximum observance of 3D geometry is required. The two processes can work both with natural silica and with synthetic ceramics having a high thermal resistance. Thanks to the capacities typical of 3D printing processes, it is now possible to produce cores representing extremely complex groups in a monolithic shape, ideal to achieve engine transfer parts, cavities for oil and water circulation, and much more.
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KNOW HOW TEAM
MODELLERIA
DIGITAL PRECISION CASTING
ZUIN
DIGITAL PRECISION CASTING RAPID PROTOTYPING WITH METALS FOR DIGITAL PRECISION CASTING - Working range up to 350mm and measuring precision from 0,1mm (aluminum, Zamac, steel). DIRECT METAL LASER SINTERING (DMLS) - Working range from 250mm and measuring precision up to 0,05 mm (aluminum, steel, stainless steel, titanium)
By combining rapid prototyping processes, which allow the printing of complex shapes in materials similar to polystyrene, with vacuum precision casting processes on gypsum, it is now possible to get real digital precision castings. Starting directly from your 3D file, different reproductions of the desired object may be printed in polystyrene. Using these “sacrificial patterns” a precision casting cluster is assembled; after being covered with gypsum, solidified and then eliminated by the burning polystyrenes, it can be used as a precision casting cavity to be filled with a vacuum casting of the chosen alloy (aluminum or zamac). The same process can be employed to obtain precision castings in alloy steel, using ceramic instead of gypsum as inert substance. With these fine solutions you can get real precision castings having dimensions up to 300mm and wall thickness of 1,6mm. They are used to test all those fine-mechanical and electromechanical components, or to simulate details deriving from die casting.
METAL SINTERING We realize high detailed mechanical prototypes thanks to the most refined sintering techniques of metal powders (aluminum, steel, stainless steel and titanium). With this technique it is possible to reproduce details measuring just a few tenths of a millimeter and get functional parts showing complex cavities or walls thickness which wouldn’t otherwise be obtained through the casting method. The surface aspect can vary from a Ra 8 roughness to a mirror finish, achieved with different treatments.
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MODELLERIA
QUICK SAND CASTING
ZUIN
PROTOTYPES “QUICK CASTING” SERVIZI DI INGEGNERIA CASTING E DI PROTOTIPAZIONE RAPIDA PERSAND ACCELERARE LO SVILUPPO DI MERCATO RAPID PROTOTYPING WITH METALS FOR “QUICK SAND CASTING” - Working range up to 1800mm and measuring precision from 0,2mm to 0,245 mm (aluminum, cast iron, bronze, brass, steel)
Directly from your CAD drawings we can realize parts in cast alloy with a very complex shape. You can get perfect casting reproductions in aluminum, cast iron, bronze, brass just in a few days and without spending too much for equipment.
These castings are carried out by manually pouring the chosen alloy in specific refractory material blocks, directly printed from 3D machines.
By combining 3D scanning systems and “Quick sand casting” prototyping it is possible to reproduce any kind of mechanical component in cast alloy. It is ideal for reproducing engine blocks, heads for engines, suction manifolds, crankcases etc.. This particular type of prototyping allows also a complete check of the preindustrial phase, thanks to specific tests which are carried out for: draft angles, minimum thickness, core and cavity separation, mold assembly, gating and feeding systems. This allows the identification of any critical point before investing in equipment.
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MODELLERIA
PLASTIC PROTOTYPES
ZUIN
POLYMERIC PROTOTYPES PLASTIC AND RUBBER RAPID PROTOTYPING - No. 3 sintering systems for nylon powders or rubber; Object printing for rigid resins and rubber with different ShA hardness; FDM; stereolithography: Working range up to 2000mm and measuring precision from 0,05mm to 0,12 mm We are a technological center where you can get prototypes made of plastic, composite plastic or rubber-like materials starting directly from the 3D file and just in a few days.
TECHNICAL POLYMERS For prototypes requiring the best reproduction of the material technical features the reproductions obtained through the sintering of powders are suggested. • Neutral polyamide (ideal for high flexible objects) • 30% glass fiber reinforced polyamide (ideal for rigid objects or tested at a temperature between 60° and 110°C) • 30% aluminum fiber reinforced polyamide (ideal for parts subject to high mechanical stress or for semi-functional tests) • Carbon fiber reinforced polyamide (ideal for motorsport parts) • Sintered rubber (ideal to reproduce big deformable objects)
NON-TECHNICAL POLYMERS For non-functional testing requirements we can realize prototypes with: • ABS filament (useful for initial tests) • liquid resins (useful for the construction of high detailed parts, such as samples for trade fairs and similar objects, also made of rigid material and rubber joined together)
SILICONE MOLDS For the most demanding technical and aesthetic requirements we realize samples obtained from silicone molds. N.B. On plastic prototypes additional operations of aesthetic finishing (sanding, painting, chromium plating, metal coating etc.) or impregnation for hydraulic use can be carried out.
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MODELLERIA
CARBON FIBER
ZUIN
COMPOSITE FIBER ELEMENTS SERVIZI DI INGEGNERIA E DI PROTOTIPAZIONE RAPIDA PER ACCELERARE LO SVILUPPO DI MERCATO CARBON FIBER LAMINATION PROTOTYPES - Both from 3D printing lamination and from mold or core lamination
Beyond giving the possibility to realize carbon fiber reinforced polyamide prototypes from 3D printing, we can also realize high-quality objects in real carbon fiber. These elements are achieved by modeling the carbon fibers with two solutions as follows:
CARBON APPLIED DIRECTLY ON AN OBJECT SERVING AS CORE SHAPE It makes the prototype construction fast and easy: the core can be obtained from a 3D file, printed with rapid prototyping techniques and with a specific catalytic treatment in autoclave. With this solution we can create carbon prototypes showing extremely complex shapes in just about a working week.
CARBON INSERTED IN A CAVITY SHAPE This technique requires the splitting up of the object shape into two shells, which are laminated separately and then assembled (except for objects having only one shell, where one side is not particularly relevant for finishing and details, for ex. motorbike housings). The need to make the cavity shape increases both construction times and costs, however it offers the best quality result and the highest fiber density, as the catalytic treatment in autoclave is the ideal one. This solution is used most for the realization of small series, where the investment for the cavity shape has to be optimized.
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MODELLERIA
ZUIN
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KNOW HOW TEAM MODELLERIA ZUIN SRL SHARE CAPITAL € 15'600 I.V. CCIAA REA NR. 374859 VAT N°N°03313250288 REA OF PADUA 302526 PADUA TRADE REGISTER N°35456/98 HEADQUARTERS: VIA ALBERT EINSTEIN, 6 35010 CADONEGHE (PD) Tel +39 049 700131 Fax +39 049 8873114 E-MAIL: info@modelleriazuin.it WWW.MODELLERIAZUIN.IT
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