The 4 Phases of the Project
1. 3D Scanning and Manual Measurements
Our team began with a complete assessment of the existing machine, combining 3D scanning with manual measurements. This step allowed us to capture every detail, providing a solid foundation for designing an improved version.
2. Design and Optimization
We then designed a new machine with two clear objectives: improving operator ergonomics and reducing cycle time. The improvements include better access to loading areas, an optimized guarding system, and a smoother sequence of operations. We also automated a key step in the process—the air blast used to remove plastic chips inside the tube which helped enhance production consistency and efficiency.
3. Fabrication and Integration
All production steps were carried out in-house: laser cutting, bending, welding, machining, and mechanical assembly. This complete integration allowed us to meet tight deadlines and ensure rigorous quality control.
4. Documentation and Support
To make operation and maintenance easier, we produced detailed user and connection manuals, which were delivered to the client along with the machine.
Machine Operation
- The operator inserts the materials (spring, aluminum rod, and plastic tube).
- The safety devices are closed to secure the operation.
- The operator starts the cycle with the push of a single button.
- The three materials are cut simultaneously.
- A notcher tool then marks the aluminum bar.
Safety
The machine is equipped with safety devices that comply with current safety standards, giving the production team peace of mind.
Results for the Client
The major improvement: the cycle time was reduced from about 20 seconds to just 5 seconds. The result is 4 times higher productivity, while also improving working comfort for operators.
This project perfectly illustrates how Omnifab transforms existing equipment into modern, fast, and safe production solutions. Our team is proud to have contributed to Altex’s operational performance and efficiency.
