Engineering Plastics

The Engineering Plastics Division of TAFE (TAFE-EPD) manufactures high precision tools and custom moulded engineering plastics at its state-of-the-art facility in Bengaluru, Karnataka, and Maraimalai Nagar near Chennai, Tamil Nadu. The imperatives of growth in the engineering plastics and tool making industries demands continuous innovations in technology and business practices. We meets this challenge by combining the most sophisticated technology with a skilled workforce, aggressive quality control systems and an unwavering dedication to customer service. Engineering Plastics Division has a primary focus on manufacturability in injection molded engineering plastics and pressure die-castings.

We view design as an upstream phase in the multi-stage operation of manufacturing. The manufacturability of a design is a measure of how successfully it can be translated from concept to computer representation and finally, into a high-quality and cost-effective physical product. A visually perfect design might be impractical to manufacture or minor changes to a design can result in significantly improved tooling and production efficiency. While computer-based technologies have made significant strides in simulating tasks of design and analysis, there has been relatively less progress in validating manufacturability.



Competencies

Product and Tooling Design

3D Product Modeling

Engineering Analysis

3D Tool Assembly Design

DFM

TOOL PRODUCTION

State-of-the-art networked
CNC machinery

Optimum hand-craftsmanship

Assemblies

Highest quality output


RESULTING PRODUCTS

Automotive

White goods and appliances

Electronics

Consumer

INJECTION MOLDING PRODUCTION

Automated,integrated shop floor

Temperature-controlled
material transport

Automated mold-presses and
assembly lines

These services embody the accumulated knowledge in engineering, developed through over 40 person-years of design and production for some of the most demanding OEMs in the nation. The focus lies in injection moulded engineering plastics and pressure die castings, where knowledge-based design validations have been successfully verified through final production in several projects.



Services

CAD

  • Surface, Solid and Assembly Modelling
  • Feature-based Design
  • Parametric and Variational Design
  • Dimensioning and Tolerencing
  • Generative and Interactive Drafting
  • IGES and STEP Interfacing
  • Applications: Pro-E, IDEAS, ICEM-Surf

CAM

  • Multi-axis generative CNC machining
  • Post-processing
  • Applications: Advanced-NC,Pro-NC

CAE

  • Plastic and metal-flow stimulations
  • Applications: Moldflow, Pro-Mold

DESIGN-FOR
MANUFACTURABILITY

  • Product geometry validation
  • Flow facilitation
  • Correct input choice for product functionality
  • Validation of material flow across tooling constraints
  • Optimizing of design process of Zero Defects, target cost
  • Continuous Improvement Program
  • Tool design for target cost, cycle time and finish

REVERSE
ENGINEERING

  • Point-sampling using high-speed contact sensors
  • Interfacing scanned data to advanced software
  • Creation of 3D product geometry
  • CAE analysis
  • DFM considerations on scanned geometry

PROTOTYPING

  • Prototypes with soft-materials using high-speed machining
  • Stereo-lithography/FDM (outsourced)

Delivery

Efficiency Considerations in Outsourcing

Today, EPD follows a predominantly off-site outsourced customer engagement model. This means we service our design requirements from our development centre in Bangalore, India. The outsourcing model offers certain economic advantages to customers. It also raises concerns of efficiency and control, brought about by geographical and time separations.

Discrete Engineering Services

  • Multiple vendors for multiple functions
  • A convoluted process
  • A one-to-many model loaded with multiple one-to-one interaction costs
  • Cycle-of-validation spans across many service vendors
  • Complicated further by separations in time and geography

EPD's Approach

  • Integrated Outsourced Engineering
  • Fewer convolutions
  • Fewer one-to-one interaction costs
  • Cycle-of-validation cuts fewer boundaries
  • Customized Internet-based project collaboration tools
  • Ultimately, Go further, in less time.

Clients

  • Ashok Leyland
  • General Motors
  • Renault Nissan
  • Toyota Boshoku
  • Visteon
  • Ford
  • Hanil Automotive
  • TATA Toyo
  • TVS
  • AMCO
  • Johnson Controls Saft
  • Exide
  • GE Healthcare
  • GE Medical Systems
  • India Japan Lightings
  • Rexroth Bosch Group
  • Lion

5

Automotives Sector

  • Ashok Leyland
  • Ford
  • General Motors
  • Hanil Automotive
  • Renault Nissan
  • TATA Toyo
  • Toyota Boshoku
  • TVS
  • Visteon

Batteries Sector

  • AMCO
  • Exide
  • Johnson Controls Saft

Healthcare Sector

  • GE Healthcare
  • GE Medical Systems

Other Sector

  • India Japan Lightings
  • Lion
  • Rexroth Bosch Group