"QUALITY ALWAYS REPRESENTS THE WISEST CHOICE AMONG MANY ALTERNATIVES"
William A. Foster
MCS Morandi is structured in such a way as to be able to carry out all the activities necessary for the construction of the mould internally, from the development of the initial concept to the start of series production, ensuring the necessary assistance during all stages of the work.
We specialize in the construction of medium / large-sized series moluds up to 35 t. We can also build prototype moulds, complete with all the necessary tuning. Before final delivery to the customer, each mould undergoes a pre-series trial, which is very important to verify its functionality and correct execution according to the design. The tests are carried out internally on our injection machines from 600 up to 2200 t, also available for third-party moulding and series production.
MCS Morandi provides all after-sales services, customized according to the specific production needs of the customer, such as: overhaul, maintenance and optimization of each type of mould, both built internally and made by other suppliers.
What we can do
The technical office supports the customer from the initial co-design phase and takes care of all aspects of the design, including simulations of filling and warpage under operating conditions, calculations and structural analysis FEM (Finite Element Method) and service of reconstruction of the shapes (Reverse Engineering).
Thanks to the use of specific and updated software according to the most advanced technologies, MCS Morandi guarantees maximum security and confidentiality at every level, especially during the delicate phase of transferring the developed data.
The quality of CATIA V6 software, used in the automotive sector, allows engineers to manage the design quickly and accurately. Possibility of reading and internal conversion of most CAD formats.
The workshop is equipped to perform all the necessary processes for the construction of injection moluds up to a weight of 35 t. The technical team is made up of specialized workers and qualified personnel, internally trained thanks to the specific know-how gained in 60 years of history.
MCS Morandi is equipped with a tool shop capable of fully and professionally managing all stages of assembly, tuning and maintenance of the moulds. Each construction phase is subjected to constant and rigorous controls that ensure the quality of the processes and the final product.
The workshop is able to handle large orders, using the following machines:
- CNC milling machines up to 7 axes and at high speed
- Lathes for machining up to Ø 650 mm
- Surface grinding machines with working range up to 3000 mm
- Precision drilling machines with the possibility of working from Ø 4 mm to a max of Ø 30 mm with a depth of up to 3000 mm
- Wire erosion up to 400 mm in height and die-sinking erosion for parts up to 3000x2000x1600 mm and table capacity up to 30 t
- Department dedicated to mechanical sharpening
- Laser welding with a working range up to 3300 mm
- Dimensional checks carried out in the company
PRE-SERIES AND THIRD-PARTY MOULDING
Managed by specialized and dedicated staff, the department offers a complete service, from pre-series trials to verify functionality up to the production of series production in a fully automatic cycle.
The injection moulding machines from 600 to 1000 t are equipped with a rotary table and satellite unit for multi-component parts.
The 2200 t injection machine is equipped with 2 injection units and an automated robot up to 3 axes.
The injection machines have a control unit for gas assisted projects and a sequential control unit for managing sequential valve gate nozzles.
The automated robot has the following technical characteristics:
- Translation axis 3500 mm
- Extraction axis 2000 mm
- Vertical axis 2400 mm
- R tilting axis 0 ° – 90 °
- Maximum total load on the wrist 45 kg
In order to optimize order costs, for moulding we can also supply:
- Construction and supply of the tested gripper, customized on customer request
- Large storage capacity for large volumes
- Direct transport management
- Direct management of transport
The technical office and the workshop are also available to their customers to evaluate individual processes on behalf of third parties that require specific laser welding and / or EDM activities, based on the following work dimensions:
- Alpha Laser 200W laser welder with working range
- Ingersoll die-sinking EDM with table
3000x2000x1600 mm and capacity up to 30 tons
MAINTENANCE, OPTIMIZATION, REPAIR OF MOULDS
Thanks to decades of experience and know-how gained in this sector, we can guarantee a competent service of maintenance, cleaning, overhaul of moulds, both built internally and made by other suppliers, and we are equipped to be able to carry out repairs, modifications and optimizations in a short time.
The mould maintenance department has an Alpha Laser 200W laser welding machine with a working area of 3300x2380x2060 mm and a die-sinking EDM with a table of 3000x2000x1600 mm and a capacity up to 30 t.
On request, we can study a customized periodic maintenance program, which is essential to keep the mould functional and efficient throughout its production life.
Our internal procedure provides for a systematic quality control and the application of strict inspection criteria during all stages of mould construction.
Each process is constantly monitored by our qualified technical personnel with a view to a continuous search for the prevention and reduction of errors.