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Process Solution Center / Application Center

Shape Process Automation's internal Process Solution Center (PSC) is designed around the customer. Whether it be a small quantity of preproduction or prototype parts, test cuts, or a high-volume, 24/7 production run, the PSC exists to meet customer's needs. Our goal is to find the process that best suits a customer's quality, throughput, and financial situation.

Process Selection

What type of process is best?

Identification of the proper process is a key element when implementing automation. To discover the most beneficial trimming method, the process experts in the PSC take a sample part and determine the best cycle time and trim quality using the most feasible trimming methods. The information is then presented to the customer, further allowing them to make informed decisions.

The Process Solution Center also benefits Shape Process Automation by serving as a means to develop new and improved trimming technology. For example, KMT’s patented Compliant Knife technology was first developed in the PSC.

Waterjet

  • Generally used when cutting carpets, dash insulators, headliners, instrument panels, headliners, various types of vinyl and foam, and others
  • Offers clean cuts at fast speeds

Router

  • Generally used on fiberglass, polypropylene, instrument panel substrates, composites, polycarbonate/PCABS, gel coat and FRP, low pressure molded PP, vinyl, acrylic, wood, SMC among others
  • Offers clean cuts through thick materials (no burrs)
  • Typically faster cutting speeds than waterjet (depending on part type)

Laser

  • Generally used on textile material, polypropylene, paint film and plastic
  • Offers clean cut
  • No water or router chips are generated
  • Extremely fast cycle times can be achieved – especially when utilizing the Scanner head

Knife

  • Typically used for flash removal or material separation purposes
  • Deflashes the parting line on injection-molded parts

Materials

What type of material is best suited for each process?

Laser

  • Generally used on textile material, polypropylene, paint film and plastic
  • Offers clean cut
  • No water or router chips are generated
  • Extremely fast cycle times can be achieved – especially when utilizing the Scanner head

Router

  • Generally used on fiberglass, polypropylene, instrument panel substrates, composites, polycarbonate/PCABS, gel coat and FRP, low pressure molded PP, vinyl, acrylic, wood, SMC among others
  • Offers clean cuts through thick materials (no burrs)
  • Typically faster cutting speeds than waterjet (depending on part type)

Waterjet

  • Generally used when cutting carpets, dash insulators, headliners, instrument panels, headliners, various types of vinyl and foam, and others
  • Offers clean cuts at fast speeds

Knife

  • Typically used for flash removal or material separation purposes
  • Deflashes the parting line on injection-molded parts

Capital Equipment

Below is a basic list of the capital equipment in use in the PSC on a regular basis. Please note that the list is not all-inclusive and that special equipment can be brought in at any time to accommodate the testing of your prototype parts.

Router Trimming

Enclosed Router Cell with:

  • R2000i Robot with a 10 hp spindle
  • Servo-controlled rotating table
  • Automatic Tool Changer Equipped with 6 tools
  • Accuracy Tools Software
  • TCPmate
  • CalMate
  • CellFinder
  • RouterWare Software
  • AccuFind Laser Sensing Software
  • Touch-Sensing Software

RT-1000 Enclosed Dual-Robot Router Trimming System with:

  • Two RPT AccuTrim R-44 robots
  • Servo-controlled rotating table with Fixture Identification
  • 3 hp spindle
  • RouterVac with Vacuum Pump Capabilities
  • 6-Tool Automatic Tool Changer
  • Accuracy Tools Software
  • TCPmate
  • CalMate
  • CellFinder
  • RouterWare

Laser Cutting

FLACS II 600W Flexible Laser Cutting System with:

  • RoboCut A600 Robot
  • Scanner trimming head
  • Servo-controlled Rotating wall

Waterjet Cutting

Dual Robot A-Frame Waterjet Cutting System with:

  • Two Shape Process Automation AccuTrim WJ-44 Robots
  • JetVac
  • Accuracy Tools Software
  • TCPmate
  • CalMate
  • CellFinder
  • JetWare Software

Knife Trimming

Single Robot Knife Trimming System:

  • Single FANUC M-16iB Robot
  • Fixed Fixture Table