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Case Studies

RM Design and Engineering, a specialist in Vacuum Formed Parts and Composite & GRP Tooling based in Warwickshire, West Midlands. The majority of the work we do is highly confidential but we have assembled the following case studies to give you a flavour of what our team can deliver for you.

We are experienced in designing, developing & supplying parts and tooling for the following sectors:

  • Motorsport & Automotive
  • Aerospace, Marine & Rail
  • Movie & TV Production (props)
  • Defence
  • Medical
  • Energy

Advanced Solutions for Luxury Car Manufacturer's Prototype Front Bumper

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Design & Manufacture of Composite Tooling for Carbon Fibre Components

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Manufacture Composite Tooling for F1 Cars from Supplied Data

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Advanced Solutions for Luxury Car Manufacturer's Prototype Front Bumper

Client: Renowned Luxury Car Manufacturer

Project: Prototype Bumper

Expertise Areas: Vacuum Formed Parts 

RM Design and Engineering, a specialist in Vacuum Formed Parts and Composite & GRP Tooling based in Warwickshire, West Midlands, was approached by a renowned luxury car manufacturer with a request to create a front bumper for a prototype vehicle. 

Challenge and Initial Steps: The client's original front bumper design was intended for injection moulding. Therefore, the first critical task was to redesign the bumper to be compatible with the vacuum forming process. Leveraging their in-house expertise, RM Design and Engineering successfully modified the bumper design to suit vacuum forming requirements.

Design and Tooling Development: Using Hexagon VISI 2023 modelling software, the team designed a vacuum forming tool. This tool was crafted in-house from medium-density model board. The state-of-the-art 5-axis CNC machine (CMS Ares), paired with Autodesk Powermill 2023 for programming, was utilized to precisely machine the tool. The final touches were meticulously hand-finished by RM Design and Engineering's skilled operators.

In addition to the vacuum forming tool, a trimming fixture was also created using low-density model board to ensure precise trimming of the final product.

Production and Execution: Partnering with a trusted vacuum forming specialist, RM Design and Engineering oversaw the production of the plastic components. Following this, the 5-axis machine was employed again to trim the plastics to the exact specifications required.

Project Timeline and Client Communication: The entire process, from the initial redesign to the final product, was completed within a four-week period. Throughout the project, RM Design and Engineering maintained open lines of communication with the client, providing regular updates on progress. The client expressed high satisfaction with the end product, praising the efficiency and quality of the delivered front bumper.

By adapting their design and manufacturing processes to meet the unique needs of the luxury car manufacturer, RM Design and Engineering demonstrated their capability to deliver high-quality, custom-engineered solutions efficiently and effectively. RM Design and Engineering is the perfect choice for any automotive engineering project. With years of experience, specialized skills, and state-of-the-art equipment, they have built a reputation as a trusted and well-regarded leader in the industry.

Design & Manufacture of Composite Tooling for Carbon Fibre Components

Client: UK-based Composite Parts Manufacturer

Project: Direct Moulds for Carbon Fibre Component

Expertise Areas: Composite & GRP Tooling, Vacuum Formed Parts 

RM Design and Engineering, a specialist in Composite & GRP Tooling and Vacuum Formed Parts based in Warwickshire, West Midlands, was approached by a UK-based composite parts manufacturer to create direct moulds for a carbon fibre component intended for a one-off production.

Project Requirements and Initial Steps: The project's success hinged on the precise design and manufacture of the moulds, as only one attempt was available to get it right. RM Design and Engineering engaged in detailed discussions with the client to determine the optimal placement of split lines and to understand the de-mould process. The collaborative design phase involved three iterations before receiving client approval to proceed with machining.

Design and Tooling Development: Leveraging their extensive in-house expertise and Hexagon Visi 2023 CAD software, RM Design and Engineering designed the moulds meticulously. Epoxy model boards were selected for the tools, and the team ensured that no gaps were present during the bonding process of the blocked stock.

Precision Machining and Quality Assurance: Using their state-of-the-art 5-axis CNC machine (CMS Antares) and Autodesk Powermill 2023 for toolpath programming, the team machined the tools with high precision. Post-machining, the moulds were inspected with the Hexagon Absolute Arm coupled with Polyworks 2023 to ensure accuracy.

Finishing and Delivery: The skilled operators at RM Design and Engineering sanded the moulds to a smooth finish, paying meticulous attention to detail. Regular progress updates were provided to the client throughout the project. The entire process, from design to the finished component, was completed within three weeks: one week for design, one week for machining, and one week for producing the part.

The project was delivered on time, and the client was extremely satisfied with both the service and the quality of the final product. RM Design and Engineering’s ability to deliver precise, high-quality composite tooling solutions within tight timelines underscores their expertise and commitment to excellence in the automotive engineering industry.

Manufacture Composite Tooling for F1 Cars from Supplied Data

Client: Renowned F1 Company

Project: Composite Tooling for F1 Car Wing

Expertise Areas: Composite & GRP Tooling, Vacuum Formed Parts

RM Design and Engineering, located in Warwickshire, West Midlands, was entrusted with a complex composite tooling project by a renowned F1 company. The task involved machining a large package of composite tooling to create the wing of an F1 car, encompassing ten different patterns of various geometries.

Project Scope and Initial Steps: The project commenced with the precise blocking of the tools using epoxy model boards. These blocks were then meticulously machined on RM Design and Engineering's CMS Antares 5-axis CNC machine. Advanced toolpath generation was achieved using Autodesk Powermill 2023 software.

Precision Machining and Quality Assurance: Each pattern was sanded to a smooth finish by skilled operators, ensuring the highest level of detail and precision. Comprehensive inspection was conducted using the Hexagon Absolute Inspection Arm coupled with Polyworks 2023 to verify accuracy and quality.

Client Communication and Timely Delivery: Throughout the project, RM Design and Engineering maintained regular communication with the client, providing consistent progress updates. The project was completed on time, and the client expressed high satisfaction with both the quality of the tooling and the level of service provided.

By successfully delivering this complex and high-precision project, RM Design and Engineering reinforced their reputation as a reliable and expert partner in the automotive engineering sector, specializing in Composite & GRP Tooling and Vacuum Formed Parts.

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