Axiam Limited: Industry leaders in plastics, diecasting, manufacturing and production.
Replacing three cast units with one simplified & saved money
AXIAM was able to cast, CNC machine, assemble and tolerance test all in house. A complete one stop shop.
- Processes used in this case study
- Process design
- Product design
- Tool design
- Engineering design
- Product testing
- Jigs & fixtures
- Tool manufacturing
- Injection molding
- Reaction & composite molding
- High pressure die-casting
- Low pressure die-casting
- Shell (cronin) casting
- Sand casting
- Heat treatment
- Sub-supplier management
Fisher & Paykel: Izona Cook-top Aluminium Rings
Only the best will do for New Zealand’s Master Chefs, which is why the 2010 winner of NZ Masterchef won an Izona Cook-top as part of his prize package. The Izona cook-top blends the performance of gas with the style and easy care of a glass cook surface and is so innovative it has taken home an international GOOD design award and a Gold for best consumer product in addition to the Stringer Supreme award at the NZ Best Design Awards.
The sleek design of the cook-top is made exponentially cooler by the fact that the gas hub rises so smoothly at the touch of a button it appears to be magic. What is it that makes the movement seem so effortless? – An AXIAM made Camlifter hiding just below the surface.
Initially Fisher & Paykel approached AXIAM with the concept as a 3 part set, each part cast and machined separately, then assembled together. Upon studying the concept, AXIAM floated the idea of combining all 3 parts into one cast unit, which would then be machined and separated at the same time. This led to a substantial reduction in initial tooling costs and ensured that each part was a perfect match for the other two pieces of the set.
AXIAM was also able to offer a ‘one stop shop’ – Casting, CNC Machining (including separation) and then assembling the set into an operational lifter ready to assemble to the Cook-top. With the design of the cook-top requiring utmost quality and precision, tolerances and quality testing are equally stringent, meaning each cook-top operates as smoothly and seems as effortless as the next.
As this style of cook-top is a completely new innovation, there were no precedence to the manufacture of these parts. This was not a problem for the AXIAM design team who looked upon the project as an opportunity to create the best and be a part of an award winning product. Something which the judges of the world seem to have confirmed.
Customer: Fisher & Paykel Ltd
532541 & 532540 cam lifter 20 & 30 PU Assy, 20 mm and 30 mm camlifting ring set which controls the raising and lowering of the gas burners on the IZONA range of Cook-surfaces.
Local / Export (Mexico) – home appliance industry
Alan Quadling, Dean Kensington.
Height 40mm lowered – 80 mm raised
22 assembly components
High pressure diecast
Trim overflow and remove runner
CNC machine on 3, then 5 axis machining center
Handwork to clear machining burrs
Assemble components together
Test, pack and dispatch as assembled unit
Initial enquiry received
Designs and drawings were completed
Tooling approved and tested
Process designed and documentation created
Product testing and sign off completed
Tight CNC machining tolerance
Assembly components fit requirement (±0.03mm)
Governing functional tolerance torque (±0.5nm)
Requirement to have minimal porosity