Thermoplastics
We can really change the game by
educating industrial designers, transit
system professionals and rail engineers
Ruben Bake, Sekisui SPI
“Collaboration and discussion are so significant in the appLab,”
says Shawn Gum, appLab applications engineer. “We can review
the 3D image with designers as many times as needed to create
the best part for their application. Difficult features are made easier
with the appLab’s advanced visual equipment. There are always
ideas to explore.”
The one-of-a-kind, application-specific MAAC Machinery
pressure former is another important piece of equipment in the
appLab, along with a standard batch oven with custom conveying
units from Wisconsin Oven and CNC mills from Haas Automation
and Thermwood. While this list of equipment may suggest
singularity, the appLab is not locked into one manufacturing
or finishing process. Rail customers can continue to collaborate
with thermoforming partners and other suppliers in a more
advanced capacity. A multimillion-dollar investment, the appLab
truly is designed as a space for rejecting the status quo and
experimenting. It began as an engineer’s dream.
“While fibreglass is a dominant material in the rail industry,
the benefits of Kydex thermoplastics have been largely untapped,
especially with weight savings of 20-40% over FRP parts,”
comments Gum. “Thermoplastics’ benefits include weight savings
ANNUAL SHOWCASE 2019 Railway Interiors International 61
RAPID PROTOTYPING
The rapid prototyping process
begins with scanning a part using
technology from the Faro laser
line probe. After scanning, the 3D
image can be adjusted digitally using
SolidWorks. The Faro laser line probe
creates an exact replica of any piece
it scans, including texture
and dimensions.
Instead of spending time
painstakingly measuring and
guesstimating part measurement,
precise models are created that
can be altered quickly, allowing
for quicker part iteration.
Rail designers, engineers and OEMs can come to the appLab
with a part, idea or drawing that can be expanded upon. The
concept will go through the rapid prototyping process from start
to finish, including reverse engineering the part, refining the
design and manufacturing a prototype tool, all within a few days.
This process is designed to establish part consistency, which the
company says can be difficult to achieve with FRP parts.
“Rapid prototyping is essential in the rail industry,” says Bake.
“In an arena where rail interiors and their design may be towards
the bottom of the list, the ability to design and deliver a finished
part quickly is key. With highly customised designs, beginning the
process earlier can streamline the process. Engineers, designers
and OEMs no longer sacrifice what they really want due to tight
timelines. Instead, the appLab is where deadlines are celebrated
as opportunities to iterate quickly.”
Technical tools
Advanced equipment, including the Faro laser line probe, allows
developers to create an exact replica of any piece that crosses the
appLab threshold. This is accomplished by scanning a part and
replicating it into a digital 3D model that can be revised seamlessly.
MAIN: The
appLab, a
new innovation
centre at
Sekisui SPI
ABOVE RIGHT:
A thermoformer
and formed part
in the appLab