West Midlands based Rojac Urethane has invested in two 7-Axis foam milling cells that can produce highly complex models and prototype parts directly from CAD files.
Based at the Automotive Components Park in Wednesbury, Rojac Urethane is well known for their ability to ‘push the boundaries’ of what can be achieved through polyurethane foam technology. Customers from a range of sectors, including Automotive Medical and Aerospace, can be supported from prototyping, through to tooling and full volume production.
When full production is to involve the high-volume output of larger PU components, for example, automotive seating, then Rojac provides customers with a bespoke development and prototyping service. This facility allows products to be fully developed and tested without the time and costs associated with prototype tooling. Designs can be fully optimised before production tooling is laid down and high-volume manufacturing commences.
A significant contributor to Rojac’s success has been the recent investment in two dedicated 7-axis machining cells. Two huge KUKA 6-Axis robots, combined with rotary machining tables utilise Autodesk® PowerMill Robot software to machine a wide range of materials. As well as utilising materials only suitable for modelling, such as expanded Polystyrene or Polypropylene, in-house moulded bespoke foam blocks can be processed. This allows items to be produced to an exact specification, mirroring the foams to be used in the full production process.
Managing Director, Duncan Blakemore commented: “We set out to exceed the speed and quality of prototype components currently available, whether in the UK or overseas. Our robot machining cells are capable of producing complex and unusual geometries, including complex undercuts and 3D objects. They provide a massive reach and 3D workspace that includes 10-station tool changers, giving automatic and flexible tooling selection for specific material removal and the best possible cosmetic finish.
“We can produce fully working prototypes that can be used for field testing, even combining different material types when necessary. For example, an automotive seat is often required to provide different levels of support in certain areas, so we machine foam blocks of different hardnesses and then assemble the components into a single unit. We can also incorporate items such as trim wires, velcro, clips and frames, as well as coat the finished assembly with a unique synthetic skin that replicates the finish achieved with the production moulded cushion.”