CTVS has completed a new concrete prefabrication mold with immediate / direct demolding: a twin-pocket mold designed to operate clamped on an automatic machine controlling the production cycle. The objective: to increase productivity while ensuring the precision of interlocking parts for drainage components.
A mold designed for vibration and automated production
In this type of application, the mold operates with vibration directly on the machine. To guarantee stability and long-term durability, the design incorporated heat treatment to stabilize welds before machining, as well as machining of the support surface to ensure precise contact between the machine frame and the mold. The large size of the chassis also necessitated a rigorous selection of machining and subcontracting operations to maintain the expected level of quality.
Three Targeted Improvements
The specifications for this mold aimed for concrete gains compared to an existing solution: reducing core wear during use, halving the changeover time (especially when switching between different product heights), and allowing the manufacture of shorter elements when necessary. The project relies on close co-design work between the teams and the client to meet these three objectives.
Ready-to-Connect Assembly and Millimeter Precision
The mold was delivered assembled with its hydraulic accessories to allow direct connection to the production machine’s circuit. In terms of dimensional requirements, the design aims for a tolerance of approximately one millimeter. To achieve this level of precision, parts were machined using 5-axis CNC, particularly for the interlocking sections.
Announced Rate: 2 Pieces Per Cycle
The two-pocket configuration allows for the production of 2 pieces per cycle, with several cycles per hour. This format is suitable for prefabrication sites seeking high throughput and consistent repeatability, especially for sanitation and drainage products.
An Export Delivery for Drainage Applications
This project was delivered to Germany, clearly intended for drainage channels. It also aligns with a strategy to expand the product range to other applications on automated machines for immediate demolding.
Demolded Channels
Exterior View of the Mold
