We’ve started telling you all about our method, showing how even the most complex projects are always based on the concepts of simplicity and precision.
We begin with your design or prototype and together decide upon the most suitable material from which to create it, seeking out the ideal and most advantageous solution.
Coining and cutting are vital initial stages and we approach these with the utmost precision and attention to detail.
After analysing the production needs we create a 3D image of the component in order to make the coining die, also calculating the outlet points through which excess material can escape.
The excess material thus produced during coining is then removed by cutting, using a cutting mould.
These stages require a great deal of experience in order to identify and understand the conditions needed for each material to be moulded. Indeed, the less resistant a material, the better it will behave and this is why semi-finished products often undergo annealing processes.
The coining die consists of two hardened steel matrices, usually of grades K110 or K340, which are created by milling or electro-erosion in which an electrode is created and the matrix is engraved from the imprint. These electrodes are copper components that reproduce the finished piece, produced by CNC milling.
In contrast, the cutting mould consists of a punch and a matrix cut by wire electro-erosion, then, in the second stage these two pieces are worked by hand or once again by electro-erosion, in order for the coined piece to be perfectly centred to enable removal of the excess material.
Finally, corrective hand-working is very important for achieving the required dimensions and for polishing and finishing. Our experience in these manual processes is essential for a good result.
While state-of-the-art machinery is a must at D.F., we also rely on the commitment and skills of those who work with us to ensure each project is successfully completed.