FLEX-CORE has their finger on the pulse of innovation and is upgrading legacy manufacturing methods by replacing cumbersome thermoformed molds with customizable 3D printed modular molds.
FLEX-CORE manufactures electrical components for monitoring, measuring, and controlling the flow of energy across the world. One of these components, the Flexible Split-Core Current Transformer, has sparked the drive towards digital transformation, eliminating hours of frustration encountered daily by their production team.
Traditional silicone casting methods can be finicky and inconsistent. Each thermoformed HDPE mold is capable of producing only clones. Each mold exists as a whole and cannot be readily updated — only replaced. The removal of each casted product requires care and takes time, while still not yielding a high percentage rate of QC-accepted parts.
Thousands of manufacturers are using FLEX-CORE transformers to monitor the current of critical infrastructure. Each one of these transformers used to be cast in silicone by hand in 25 year old molds. We no longer have to force out each casting, increasing production success rates and employee happiness.
The new 3D printed molds created by FLEX-CORE take the principle of traditional silicone casting methods to the next level by bringing mold production in-house and enabling new functionality and customizations that were previously impractical. Each 3D printed mold uses magnets to solidly hold the mold walls to the metallic base, clips and risers to hold the split-core transformer in place, and includes debossed elements to identify the model of each cast part, all in one go. Casted part removal is made easy—the tension band is released, the retaining clips removed, and the 3D printed mold splits apart leaving each casting intact, unmarred, and ready for the next phase.
Adding functionality to our 3D printed molds is so easy, we’re now able to add debossed features like product identifiers during the casting process. Positioning is more precise and exact every time with the 3D printed mold, saving operator time. Once the rubber is poured you’re trusting that the end product will be usable. With the 3D printed molds we know each one will be perfect.
Trusted production grade materials, partners that are an email away, and in-house 3D printing capabilities help the FLEX-CORE team stay current on the latest innovations.
Ready to cast aside the headaches and rigidity of traditional manufacturing methods and workflows? Let the engineering and additive manufacturing experts at IC3D help solve your toughest 3D printing challenges.
