5-Axis Aerospace Component

June 2019

To test out our new 5-axis Matsuura CNC machine, we manufactured an aerospace component with no perpendicular features. .

We started the project by conceptualizing how the machining processes and tooling would need to interact to create the component. We then created the g-code program using Mastercam and then cut a test piece to check dimensional accuracy.

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Robotic Tapping Machine V2

May 2019

We are currently revisiting an earlier project to attempt to further streamline the manufacturing process. Our semi-automated thread forming cell is now being converted to be fully automatic. The original design was used as a foundation to further develop the automation cell.

The new system incorporates a custom vibrating feeder along with a pneumatic indexing system.

Revised design of robotic tapping machine

Revised design of robotic tapping machine

Fully automatic loading and unloading for thread forming

Fully automatic loading and unloading for thread forming


Fuel Injection Component Development

February 2019

We developed a manufacturing process to produce a new fuel injection brazed junction block. The process began in late 2018 and finished early 2019, the entire process from beginning to end was developed at Dieform.

We have now signed a deal to produce a machined component for the new 2020 Ford Bronco. The component will exceed 350,000 yearly volume and will be entirely manufactured in our headquarters in Mississauga Ontario Canada.

 
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Excavator Differential Machining Fixture

January 2019

Dieform produced a 90” x 50” machining fixture for a family of excavator differential steering axles.

The project started with initial design concepts to ensure all components could modularly fit on a single rigid base. Afterwords detailed design and validation were conducted in Solidworks. Machining toolpaths and cutting loads were tested in Mastercam. The project then went to the shop floor and was constructed. Testing was done and improvements to rigidity were made.

Modular Design to fixture multiple family of parts

Modular Design to fixture multiple family of parts

Fabricated and machined fixture being used on 5-axis CNC machine

Fabricated and machined fixture being used on 5-axis CNC machine


Robotic Tapping Machine

July 2018

In order to minimize the cost, Dieform designed and produced an in-house semi-automated thread forming system. The design utilized a custom work-holding hydraulic jaw and bi-directional pneumatic loader/unloader.

All computational logic and software was done in-house along with manufacturing.

Prototyping robotic system

Prototyping robotic system

Finalized automation cell

Finalized automation cell


Welding Fixtures

July 2018

Dieform can take weldment designs and produce custom tacking and robotics welding fixtures. Fixtures can be fully automated or equipped with manual toggle clamps.

The pictures below are tacking fixtures for Caterpillar excavator motor mounts.

Solidworks  model of modular welding fixture

Solidworks model of modular welding fixture

Fully manufactured and tested welding fixture

Fully manufactured and tested welding fixture