Engineering of products is made using 3D software, including each step from sketch, down to virtual assembly. Our preferred engineering software are of Autodesk brand (Inventor and AutoCAD).
Once the design is considered final, it is checked through FEA (Finite Element Analysis), in order to simulate the effect of external forces acting upon the final product during real life exploitation.
Main steps of engineering are:
- EDO (Engineering Documentation Order) issued by the originator, or the company management. This order includes all particularities of the product, all input from the involved parties, and the originator’s approval for the first engineering phase
- D-FMEA (Design Failure Modes and Effects Analysis) meeting with all interested parties in order to highlight the possible failures and their effects on the functioning of the product in rea life exploitation
- Second phase of engineering, taking in considerations the output of the D-FMEA meeting as input to the engineering activity. In this phase a second look is taken into the standards and technical specifications which govern the product, in order to maintain conformity with such provisions
- Second D-FMEA and prototyping
- ESL (Engineering Shopping List) which includes all the components of the product, starting with raw material, a kind of recipe of the final product
- ERO (Engineering Release Order) is given by the originator or the company management, after all prior steps have been concluded with success
Below you will find the short description of one of our projects, from A to Z, to exemplify the procedure given above.
One of the main objectives of our company is development of new products. This particular project targeted engineering of a spill-box to be used in relation with storage, handling and transportation of hazardous substances. There were commercial and technical provisions which had to be taken into consideration, but without the support of a Euro Norm, which would have made our lives easier.
In this situation, TRIPLAST started a market survey with existing and potential clients, collecting as many information as possible to guide the engineering process, to steer the product characteristics into a most widely desired shape. Based on the information gathered from the market, the following minimum criteria were set:
- Minimum volume: 220 litres
- Upper deck must be able to hold firm a Euro Norm pallet (1200x800mm), or a grating of the same dimensions
- The upper pallet support must be able to channel a potential spill into the retention area
- The spill-box must be movable using standard forklift (manual or motorised)
- Spill-boxes must be stackable, in order to take up minimum possible space
Picture on the right is that of the first product variant.
Immediately after finishing the first 3D model, a new FMEA meeting was held and improvement measures were proposed to fit better the intended use, production issues, stability, rheology matters, and similar. The main change in design was replacing the two support columns in the retention bay with one sturdier support column, which assures better material deposition and better handling in the production process.
After all the adjustments, the new 3D model was presented, this time the acceptance was in unison.
The 3D element of product was verified in Stress Analysis Inventor, in order to see probable deformation and structural behaviour of the product under the load of a Euro Norm pallet and that of two fully loaded barrels. The analysis was successful with positive results even using various wall thickness values.
Before manufacturing of the mould, we 3D printed a prototype, which is common practice within TRIPLAST. We use Dremel Digilab 3D45 printer for these fun activities.
Retention tank mold
Initial holding tank
Holding tank after modification
The mould of the spill-box was finalised in January of 2020. Immediately after reception of the mould, test production was carried out, followed by product validations. Various types and quantities of raw material were used, in order to create the technological file of the product, a kind of recipe. After standardisation, the final product was subjected to laboratory testing within INCD-URBAN facilities in Klausenburg. The testing certificate is to be found below.