FOUNDRY

The many automations implemented by Compi benefit of customized and shaped trays to handle both castings and machined parts all along the production line. The ABS thermoformed tray in the picture is an example.

The extremely high volume of Nozzle Ring production, requested shaped trays to be handled by robot arms and stored in an optimized way. The ABS tray in the picture is internally produced by molding injection.

They are produced in different sizes, working as friction element of the steering joint. The used material is POM and the volume of production is around 100.000 Pcs/year.

Compi produced many models of water pump impellers, using different PPS-GF ratios. Pierburg commissioned a volume of more than 1.500.000 Pcs/year. The metal bushing is also produced by Compi, inserted in the mold and then checked at 100% for the inner diameter. Such a check is fundamental to guarantee the impeller correct functionality.

The bike windshield is an extremely delicate object because it has to be free from any imperfection: nothing from the material itself, nor from the manipulation and the working cycle. Made in polycarbonate, the model in the picture was supplied to Honda for a volume of 20.000 Pcs/year. It also required a silk-screen print (the bottom black area) and the further assembly of a rubber sealing clipped all along the edge.

The helmet compartment of scooters often has an inner coating made of a specific fabric, mainly for insulation reasons. Compi thermoformed and profile-cut about 20.000 Pcs/year.

The application is motorbike by Honda. The product is made in two shells which have different surfaces, different functionalities and therefore different specifications. Compi produce the two components in PP-GF15, by using the gas assisted injection molding. This object is a classic example of technical and design specifications to be respected at the same time.

The model in the picture is for a Honda Scooter application and it has a considerable size if compared to many other motorbikes. The material used is PP, co-molded with metal inserts.

The Nozzle Ring, beside the high precision required by the assembly, has components made of quite costly materials. Add to it the extremely high production volumes (about 6.000 pcs/day) and the many variants (often due to minimal dimensions of some sub-components), and the project will acquire a consistent complexity. Compi implemented a fully automatic line, able to deal with all the variants in continuous production.

The application is a Fiat engine, taken as Tier1 for a volume of 250.000 Pcs/year.

The application is a variable geometry turbocharger for an Isuzu engine. The customer required INOX instead of the more common cast iron, for a volume of 100.000 Pcs/year.

This was the only project taken as Tier2 with the casting supplier. The application is a VW 1.4L engine for around 100.000 Pcs/year. At the very end of the cycle, it was foreseen the screwing of a sealing cap for each cooling circuit interface; all automatically processed.

The application is a Nissan engine which required a water cooling of the turbocharger. This means additional machining to implement the cooling circuit internally at the BH, and their consequent leak test. Small assemblies are also included (welding of leverages), all for a volume around 200.000 Pcs/year.

The bearing housing represents the heart of the turbocharger. The machining phases that allow the bearing functionalities need a considerable precision. The air cooling generally makes the design simpler and more compact. Though the project reached a very high production volume: 900.000 Pcs/year, so requiring fully automated lines all long the cycle.

The application is a medium size VW engine, to be produced in high series (about 500.000 Pcs/year). The particularity of this CC is the integration of the bypass Valve: The interface that hosts it, requires a dedicated sand core, to be glued to the “main one”. Since the high volumes, the gluing process had to be carried on by a robot working by side of the sand core shooter. Compi also internally produce all the trays needed for the handling of such a delicate product.

The application is a one-cylinder engine, Liquid Cooled, for a Piaggio motorbike. The casting is produced in Low Pressure with a double cavity mold which had sliders on all the sides. In particular the cooling circuit was the most delicate part because of the sand core: very low thicknesses are tricky to be shot and also to be removed from the casting.

The application is a big Maserati engine, bi-turbo. The turbo-manufacturer technology imply the “open scroll” design. Such a feature, recalls a whole set of production requirements which define a specific kind of casting. Furthermore, the engine layout needed an air inlet interface, integrated in the Cover and not aligned with the turbocharger main axis. That brought to the use of an additional and dedicated sand core.

The application is a medium size VW engine, to be produced in high series (about 500.000 Pcs/year). The manufacturer uses a “closed scroll” design and such a feature, recalls a whole set of production requirements which define a specific kind of casting. The sand core positioning in the mold, the de-coring, and the machining become critical phases of the production cycle, especially due to the very high volumes. The de-coring (and finishing) of the casting is so assigned to an automatic isle, as well as the after-machining finishing phase. Washing, assembly, leak test and dimensional controls are all integrated in a double-robot closed isle.

Dal 1994 Compi fonde tecnologia e spirito di squadra per ottenere la sua competitività.I tanti processi che Compi ha saputo sinergicamente implementare negli anni gravitano intorno alla fonderia di alluminio.

Dal 1994 Compi fonde tecnologia e spirito di squadra per ottenere la sua competitività.

I tanti processi che Compi ha saputo sinergicamente implementare negli anni gravitano intorno alla fonderia di alluminio.

Dal 1994 Compi fonde tecnologia e spirito di squadra per ottenere la sua competitività.