DYNASTAR SKIS

Problematic:

• Produce a competition ski tip protector offering mechanical protection during impact and provides a modern design to the overall aesthetics of the ski. Moreover, the tip protector must optimize the sliding of a ski over a gate.
• Design a mechanical fastening for the part that is adapted to mass production assembly.

The FONDEX solution:

• Establishment of specifications
• Original product design
• Production of a specific deep drawing and stamping tool
• Development of bar turned inserts
• Development of the weld assembly
• Research for a finish that is adapted to the product visual
• Tests and analysis validated by the client

"A part worth the gold for a perfect run" Read our brochure

GAS MASK - GROUPE BACOU DALLOZ

Problematic:

• Produce a deep drawn part in one stroke of the press and producing the finish on a mass production product with significant safety standards (tightness) and mechanical constraints linked to its shape. In civil and military versions.

Solutions:

• Development of an NC-driven transfer tool that is able to produce a drawn part in one stroke of our 250 ton press.
• Use of a 250 T press with a 2 meter bed.
• Design of a thread performed by beading in hidden time on automatic exit press exit.
• Choice of a partner capable of producing the finish and surface treatment (alodine then paint or anodic oxidation)

Result:

A partnership that has lasted for over twenty years.  A product that is distributed all over the world for civil and military use.

SAFETY HAMMER - SNCF / RAILWAY MARKET

Problematic:

• Design a window breaker hammer adapted to the new types of windows in TGV trains by an in-house designer.

• Engineering and analysis of the technology and materials required for manufacturing.
• 3 hammers using different product components
• Engineering, tests and choice of assembly and finishing modes
• Tool design
• Search for sub-contractors
• Negotiation of a manufacturing licence agreement

Result:

FONDEX is the official supplier of window breaker hammers for all TGV carriages in France and all over the world: Eurostar, Korea, SNCF (TGV/TER), Belgium, Spain.

CONNECTOR SUPPORT - GENERAL MOTORS

Problematic:

• Produce an assembly including a stamped lug, a tapped insert then clipping a plastic part and taking into account the cost and technical restrictions in the automobile market.

FONDEX Solutions:

• Design and development of a stamping tool for lock beading assembly, test assembly and plastic insert clipping tests

Result:

This product is perfectly functional; many other products under development with this client in France and in the USA

MOUNTING FOR MOTORIZED AWNING - SOMFY

Problematic:

• Produce an assembly of safety units designed for mounting an electric motor in the building sector which is equipped with a plastic hinge in its center; several mechanical restrictions as well as cost constraints

FONDEX Solutions:

• Design and development of a stamping tool to produce the bracket (several versions), a deep drawing tool to obtain a hinge clamp (2 versions) and purchasing of the hinge (2 models)
• Development of a weld assembly process by resistance butt welding

Result:

This product is perfectly functional; the client is very satisfied, many other products have been developed. View the parts assembled