Complex geometries, robust alloys and maximum lightness: a challenge won in the automotive sector

Incoming Request

One of our automotive customers asked us for support to work out a particularly challenging job: the aim was to create a family of supports for a hydraulic shock absorber connection for one of the main automotive OEMs, which had to combine characteristics of lightness and strength.

In addition, the limited mounting space and high production volumes had to be taken into account.

Project Management

For this project, our team had to identify the ideal solution to satisfy the several technical and production aspects involved.

The stringent need to save weight and the narrow assembly spaces forced us to develop a complex casting geometry with extremely thin wall thicknesses, bordering on feasibility.

In order to meet this need and at the same time guarantee the necessary resistance requirements, we have selected a special alloy with high mechanical properties.

Despite the complexity of the geometry of the casting we have engineered and built the toolings suitable for satisfying the high requirements of mass production, as well as a fully automated cell for high-frequency machining to guarantee an excellent productivity and the hedging of the necessary capacity.

Benefits to our Customer

We’ve joint a project that presented particularly challenging aspects and we’ve  successfully completed it, creating production solutions that satisfied both the technical-quality and functional requirements of the requested products, in compliance with the incoming cost and capacity constraints of our customer.