Switch cabinet profile / Industry

Task: How can control cabinets with roll-formed profiles be assembled faster and more flexibly on site?

Challenge

Development of a machine-falling part (without manual reworking) from two components for series production. Consulting and realisation from prototype to technical specification to process optimisation of the complete supply chain. Claim of the customer: Halve costs, multiply robustness.

Our solution

By modifying and simplifying the add-on parts as much as possible, a complex injection-moulded part can be replaced by a simple plastic strip. The result is a proven system component that is used in many electrified vehicle series as a standard component by German car manufacturers.

Customer's quote

The excellent and goal-oriented cooperation with Profilmetall has always been a great pleasure. Profilmetall's technical solution competence was the basis for successfully bringing our development into series production.

Spring strip / Mobility

Task: How can a spring profile be attached to a plastic part made by injection moulding for series production as economically as possible?

Challenge

Development of a machine-produced part (without manual reworking) comprising two components for series production. Advice on and realisation of prototypes based on the technical specifications, through to series optimisation of the entire supply chain. Customer requirement: Halve the costs, quadruple robustness.

Our solution

Modification and maximum simplification of the mounted parts to replace a complex injection moulded part with a simple plastic strip. This produces a dependably system component that is used as a standard part in many electrified vehicle series' by German automotive manufacturers.

Customer's quote

The outstanding and purposeful cooperation with PROFILMETALL was always a pleasure. PROFILMETALL's technical problem-solving skills was the foundation for launching series integration of our development.

Profile support / Interior

Task: How can we switch to a new system methodology in just 6 months, without placing series supply at risk?

Challenge

Optimisation of the component geometry and integration of additional requirements for mounted parts with a very short lead time. Customer request: Reduce assembly workload and improve flexibility.

Our solution

Input from lateral thinkers and consultation with experts in a cohesive team lead to the production of a new component that still permits the use of all current mounted parts. Transport weights and volumes are reduced and assembly times cut as well. Readiness for series supply is therefore reported just five months after the first technical discussions.

Customer's quote

The smooth process of series roll-out for the new profile in such a short time was outstanding. We feel perfectly cared for.

Plaster profile / Construction

Task: How can two components be combined to form a complex geometry and thus extend the technical lead of the façade profile?

Challenge

Processing stainless steel and galvanised steel with one roll forming tool, combining several individual profiles into one profile cross-section, many asymmetrically distributed holes, partial application of an adhesive strip within the roll forming process.

Our solution

We developed a process for a roll-formed profile in which both steel and stainless steel can be formed with a roll-forming tool, in combination with partial application of an adhesive strip. The result is a ready-to-install façade profile in numerous variants. This façade solution is more stable, can be used in galvanised steel without a plastic edge, and is considerably more sustainable as a stainless steel profile. In addition, the compact profile solution reduces the variety of parts to the relevant function and simplifies storage and handling in the supply chain.

Customer's quote

I wouldn't have thought that, almost perfect the first time - to be honest, I only trusted Profilmetall to do that.