Why Design Teams Depend On It: How Fortuna Uses Digital Design to Solve Stamping Defects.

Fortuna Metals is a renowned manufacturer specializing in sheet metal fabrication. The company's commitment to innovation and quality has made it a trusted partner for various industries, from automotive to aerospace. Digital design plays a pivotal role in enhancing their production capabilities, allowing them to tackle some of the most pressing challenges in stamping.

Why Digital Design?

Understanding the Challenges in Stamping Processes

Stamping processes can introduce several defects that impact the quality and efficiency of the final product. These defects include:

Common Stamping Defects

• Die Wear: Over time, dies can wear out, causing uneven cuts and shifts in the part dimensions.
• Material Bending Issues: Incorrect pressures or improper bending can lead to deformation or cracks.
• Misalignment: Imbalanced pressures or misaligned tools can result in parts that do not fit as intended.
• Springback: The tendency of certain materials to deform after bending can cause part misalignment.

An Overview of Digital Design Tools and Software

Digital design tools and software provide designers with a powerful suite of capabilities to craft precise and efficient molds, dies, and tools. Here are some key tools used in sheet metal fabrication:

Key Digital Design Tools

• CAD Software (Computer-Aided Design): Allows designers to create detailed 2D and 3D models of parts and assemblies.
• CAM Software (Computer-Aided Manufacturing): Converts design files into machine code for CNC (Computer Numerical Control) machines.
• Simulation and Modeling: Enables virtual testing and analysis of designs to identify potential issues before production.
• Additive Manufacturing Software: Provides capabilities for rapid prototyping and iterative design improvements.

These tools streamline the design process, enabling engineers to simulate various scenarios, test fit and performance, and make necessary adjustments before moving to the physical manufacturing phase.

Benefits of Digital Design Tools

• Precision: Ensures accurate design and tolerances, reducing the likelihood of manufacturing defects.
• Efficiency: Streamlines the design-to-manufacture process by minimizing changes in later stages.
• Cost Savings: Reduces material waste, rework, and production time by predicting and mitigating potential issues.

By leveraging these tools, Fortuna can achieve optimal design outcomes that meet stringent quality standards.

Fortuna's Approach to Digital Design in Solving Stamping Defects

At Fortuna, the integration of digital design is a comprehensive and systematic approach. This involves:

Step-by-Step Process

1. Initial Design: Engineers use CAD software to create detailed 2D and 3D designs of parts and assemblies.
2. Validation and Simulation: Designs are validated through simulation and modeling software to detect potential issues early on.
3. Optimization: Any detected issues are resolved through iterative design adjustments.
4. Prototyping: Rapid prototypes are created using additive manufacturing to validate the design in a real-world context.
5. Tooling and Manufacturing: Final designs are converted into CNC code for tooling and manufacturing.

Example of Success

One notable example is the redesign of a component that was experiencing excessive material bending during stamping. By using CAD and simulation software, engineers identified the root cause of the bending issue and made precise adjustments to the die. This led to a 30% reduction in bending issues and a 20% improvement in material utilization.

Table 1: Comparison of Traditional vs. Digital Design Methods

Metrics and Outcomes

• Reduced Scrap: Digital design helped reduce the scrap rate by an average of 20% across all components.
• Improved Quality: Consistent and high-quality parts were produced, meeting stringent quality standards.
• Increased Efficiency: Production time was reduced by 15%, leading to increased throughput and lower costs.

The Future of Digital Design at Fortuna

Digital design is not just a trend but a necessary evolution in manufacturing. Fortuna Metals is committed to staying ahead in this digital transformation. Future initiatives include:

Upcoming Projects

• Continued investment in CAD and simulation software
• Development of new tools and technologies to further enhance design capabilities
• Ongoing training and education for engineers and designers

Vision

Fortuna aims to integrate digital design seamlessly into its manufacturing processes, ensuring continuous improvement and innovation. By leveraging advanced digital tools, the company can achieve unparalleled precision, efficiency, and quality in its stamping operations.

In conclusion, digital design is not just a solution to stamping defects but a strategic advantage for Fortuna Metals. It ensures consistent quality, reduces costs, and enhances productivity, all of which contribute to the company's success.

Would you like to know more about how digital design can change your stamping processes? Contact Fortuna today to learn how we can help you achieve unparalleled quality and efficiency.