CA Stampi invests in technological innovation with the acquisition of the ONA IRIS6+, a new-generation EDM machine for high-precision molds and complex geometries.
Summary
- Why we chose this technology
- Complex geometries: our new standard
- Digitalization: How we reduce errors and times
- Our commitment to sustainability
- Commitment to excellence
- FAQ: High-precision molds and EDM technology
Continuous innovation has always been our strategic cornerstone in the construction of high-precision molds. We recently acquired the ONA IRIS6+, a latest-generation die-sinking EDM machine that replaces previous equipment, bringing a significant qualitative leap in our production capabilities.
Why we chose this technology
We selected the ONA IRIS6+ to meet our customers’ increasingly complex requests for the production of plastic molds for critical sectors. This EDM (Electrical Discharge Machining) machine allows us to process parts weighing up to 4,000 kg on a 1200×800 mm table, allowing us to produce large molds with tolerances in the order of a few hundredths.
The 100-amp digital generator is dynamically configured based on operating conditions. This intelligent approach allows us to optimize each erosion phase, reducing electrode wear to levels unthinkable compared to previous technologies and dramatically improving the processing times we can offer our customers.
Complex geometries: our new standard
precision mold production to the next level. Thanks to controlled electrical discharges, we create complex three-dimensional shapes, sharp edges, very deep ribs, and cavities with cylindrical or conical profiles that would be difficult to achieve with traditional milling.
minimum roughness of 0.08-0.1 µm Ra, ensuring excellent surface finishes and significantly reducing post-polishing processes. Furthermore, thanks to multi-axis interpolation with volumetric compensation, we can handle intricate geometries while maintaining rigorous dimensional accuracies.
Digitalization: How we reduce errors and times
The ONA IRIS6+’s integrated 3D simulation allows us to fully visualize each project before execution. This tool allows us to identify potential critical issues and optimize machining strategies. We simultaneously monitor over 30 erosion parameters through an intuitive interface, allowing for real-time checks and immediate corrections.
This advanced digitalization generates tangible benefits that we pass on to our customers: reduced programming errors, minimized rework, and optimized production cycles. These aspects are particularly relevant when we tackle complex projects for automotive molds or medical applications that require high quality standards.
Our commitment to sustainability
We also invest in advanced technologies with a focus on sustainability. The integrated eco-filter ensures cleaner operation, while electrode savings and waste reduction allow us to offer more environmentally and economically efficient production processes.
For managers involved in product industrialization, we transform these characteristics into measurable advantages: optimized delivery times, low operating costs and consistent quality in series production.
Our commitment to excellence
The acquisition of ONA IRIS6+ consolidates our position as a reliable partner for precision components and complex projects. We combine machining power, micrometer precision, and advanced digital control to address the most demanding challenges of modern industrialization, ensuring excellent results from prototyping to series production.
To learn more about the technological capabilities of EDM, ONA Electroerosion offers detailed technical documentation on the latest generation of EDM systems.
For more information, contact our technicians.
FAQ: High-precision molds and EDM technology
1. What is meant by high-precision molds and what tolerances can be achieved?
High-precision molds are equipment designed to ensure dimensional tolerances in the order of a few hundredths (hundredths of a millimeter). With advanced technologies such as ONA IRIS6+ die-sinking EDM, it is possible to achieve surface roughness of 0.08-0.1 µm Ra and extremely rigorous geometric accuracies. These precision molds are produced through processes that do not involve mechanical contact, eliminating deformations and ensuring complex geometries, sharp edges, deep ribs, and intricate cavities . Micrometric tolerances are essential for sectors such as automotive, medical, and electronics, where even minimal dimensional variations would compromise the functionality of the finished product and the quality of the assembly.
2. What advantages does EDM offer for the production of large molds?
Die-sinking EDM is the ideal technology for large molds thanks to its ability to machine parts weighing up to 4000 kg while maintaining micrometric precision. Unlike traditional milling, it does not generate mechanical stresses that could deform large components. The ONA IRIS6+ has a 1200×800 mm worktable, allowing the creation of complex three-dimensional geometries even on large molds. The 100-amp generator guarantees high processing speeds without compromising quality. Furthermore, integrated 3D simulation allows for planning complex machining operations , reducing errors and optimizing execution times, a crucial aspect when processing large components with significant material costs.
Is EDM preferable to milling for automotive molds?
Automotive molds require complex geometries, hard materials, and tight tolerances, which EDM can manage, in some cases, more effectively than milling. This technology allows for the machining of special hardened steels without deformation, creating sharp edges, deep cavities , and thin ribs that would be impossible with mechanical tools. The absence of cutting forces preserves dimensional stability , essential for critical components such as body parts, cabin interiors, or engine components. Significant reduction in electrode wear and digital control of over 30 parameters ensure repeatable production. For the automotive sector, where complex geometries, consistent quality, and reduced lead times are essential, EDM offers essential competitive advantages over traditional mechanical machining.
4. How is precision ensured in large plastic molds?
Precision in large-scale plastic molds is ensured through advanced technologies that compensate for dimensional issues. The ONA IRIS6+’s multi-axis volumetric compensation automatically corrects any deviations during machining, maintaining centesimal tolerances even on complex surfaces. The real-time monitoring system of over 30 parameters allows for immediate adjustments, while pre-machining 3D simulation identifies potential issues. Electrical discharge machining eliminates mechanical stresses that could generate post-machining deformations, particularly critical in large molds where deviations of even microns are amplified. The digital generator dynamically adapts the discharge energy to the geometry and material, ensuring a uniform finish and consistent precision across the entire mold surface.
5. What are the production times for precision molds using advanced EDM technology?
Production times for precision molds with advanced EDM technology depend on geometric complexity, dimensions, and required quality specifications. The ONA IRIS6+, thanks to its 100-ampere generator, significantly reduces machining cycles compared to traditional EDM machines. Preventive 3D simulation eliminates programming errors that would otherwise cause rework, while digital control automatically optimizes each erosion phase. For medium-sized automotive molds, lead times can range from a few weeks to one to two months, including design, simulation, machining, and testing. The significant reduction in electrode wear reduces machining and setup times. Digitalization also allows for the programming of complex machining operations during production downtime, optimizing overall project planning.
For more information, contact our technicians.