Rosti

SERVICES & TECHNOLOGIES

Rosti Design Analysis & Optimisation

"Right First Time" has evolved from a process quality concept into an all embracing goal for Product Creation, Optimisation and Execution. Within Rosti "Right First Time" includes: Geometries, Materials and Processes our advanced analytical tools can predict: material cost, process time, process yield and therefore designs can be optimised before investments are committed. Ideally Rosti would prefer this to be employed as a "front end" development service which influences design at the concept stage but it is also a powerful post tooling "problem solver".

An optimised design reduces total inputs in manufacture and delivers lower costs and a greener product.

Rosti employs the latest technologies to select materials, validate component designs, develop tool designs and optimise its processes. This ensures that innovative concepts are achievable and lowest cost in production.

High-end software delivers Expert Analysis in four distinct areas:

Modelling & CAD with inter-operability in Unigraphics NX, Pro E and Catia

Ansys Finite Element Analysis validates functionality in design. New and modified products are fit for purpose

Autodesk Moldflow Insight (AMI) optimises part design for cost-reduction and risk avoidance – and tool design to reduce time to market and maximise the process window for consistent high quality in the final product

Computer Aided Design (CAD)

The use of ProE, Unigraphics NX, Catia and Autodesk Mechanical allow complete inter-operability in a diverse range of industries, from consumer lifestyle and life sciences to automotive and business machines. We can interface with our customer's designers and engineers in any location globally to deliver the right solution.

Rosti's technical teams undertake cost down analysis and generate initiatives, offering fresh ideas to continuously improve competitiveness in current products. Rosti also supports new product creation optimising new product designs and identifying metal-to-plastic conversion opportunities that exploit the latest emerging processes and materials.

In addition to 3D modelling and 2D drawings, our advanced CAD capabilities include fast, accurate wall thickness evaluation in complex geometries and validation for tooling design.

Finite Element Analysis (FEA) – Structural Analysis

We use Ansys software to ensure that products are fit-for-purpose, with the digital verification of concept designs before a commitment is made to tooling. The ability to simulate and optimize the mechanical performance of plastic parts and sub assemblies under specified loading and thermal conditions is invaluable to speeding up an accurate, viable product creation process. Various 'what if' scenarios can be evaluated early in the design process, ensuring that the correct design and material choices are made. Having confidence in the ability to achieve certain performance criteria can in many cases avoid the time and costs associated with prototype tooling.

Autodesk Moldflow Insight (AMI) – Part Optimisation

Part and mould tool optimisation is undertaken by Rosti's expert team, using the highest level of Autodesk Moldflow software products. This advanced plastic flow simulation ensures that a wide range of typical moulding defects are identified and avoided. The ability to predict how plastic parts fill, shrink, cool and warp gives a powerful and in-depth insight to the injection moulding process, allowing critical decisions to be made with confidence – and significantly reducing project risk.

This upfront approach to plastic part analysis is the key to Rosti's right first time approach to manufacturing - and the benefits are evident in the reduced time to market resulting from inherent part quality improvements. Our general aim is not only to achieve a process that works - but rather a process which is the most efficient and effective it can be, ensuring lowest PPM performances.

Autodesk Moldflow Insight (AMI) – Mould Tool Optimisation

Moldflow Insight software is employed to optimise injection mould designs prior to manufacture, we also support tool commissioning with Design of Experiment protocols to ensure the qualification process is achieved on time.

For example, modelling the proposed cooling channel layout allows 'hot spots' in the tool to be identified - and where possible, corrective action is taken to ensure more uniform heat dissipation. Analysis of the complete mould construction provides an in-depth understanding of the interactions between the various components, from the effect of copper alloy inserts and the prediction of pressure requirements in hot runners and mould cavities, to polymer freeze time and part deflection estimates. Our advanced software capabilities also allow the simulation of more specialized processes, including Gas Assisted Moulding. Making changes to a tool after it has been built can be time consuming, difficult or detrimental to tool structure; applying controls and building optimized solutions from the outset can significantly minimise these downstream costs and delays, by identifying problems via on-screen 'digital tool trials'.