Design Improvements

We were requested by a large Gt Yarmouth business to copy a tube bending fixture by digital scanning and reproduce it as new.

We completed the digital scanning, but whilst doing this, we found many ideas which would actually improve the product, this included the materials which were originally employed, along with various limits and fits of the assembly. The client discussions didn’t end there because as we critically analysed the various features of the tool with the users, further improvements were realised from the operating perspective also.

The final design embraced a new concept, which offered good improvements in use and durability, along with fully supported and easily repeatable CNC machining processes. We implemented materials into the design, which we currently use and have expert knowledge of, such as the composites which we use for patterns. By using a hard grade for the tube formers we could produce very accurate multi tube formers for a fraction of the price in aluminium.

Click on a gallery image below for a description of the process:

This is the original tool, made from steel and aluminium, much altered over a 10 year life.

This is a completed roll with tubes trimmed and welded. Ready for its next operation.

This is the assembled new tube winding fixture as delivered.

This is the first stage of loading the preformed and welded tubes and manifold to the new fixture. The tolerances and spacing’s on this tube supporting segment provided some challenge.

This shows the partial assembly of the fixture.

This shows the fully assembled fixture, ready for sending to the winding station.

Commencing to wind the tubes. The new fixture allows a clean and continuous wind.

The fully wound tubes.

Part dis-assembled fixture showing the key components.

The completed coil with just the former to ease out.