At Tfb, we offer automated industrial solutions for the finishing of plastics: welding, cooling, assembly, product handling, mounting of components, testing, marking, and traceability.

We propose solutions for every need, both standard and customised.

Automatic machines, semi-automatic machines, and fully automated robotic systems for thermoplastic components manufactured using the different moulding technologies (injection moulding, blow moulding, rotational moulding), and in all other sectors where an increase in production with full quality control is required.

We specialise in handling all the requirements of moulded pieces using injection technology.

At Tfb, we offer automatic systems, special machines with interchangeable equipment to meet all processing requirements.

Moreover, we completely manage the handling and traceability phases as well as all the necessary tests to guarantee correct processing.

POST-COOLING MACHINES

We produce special post-cooling machines for cooling freshly moulded parts, using water and air technologies and interchangeable jigs.

The injection moulded part is cooled with cold or ambient air.
The still-warm moulded part is fixed to a clamping jig which is placed into a special cooling cabinet. The right amount of cold air is then injected inside this cabinet.
This operation allows the part to cool while maintaining its structural and dimensional characteristics.

WELDING

We specialise in the welding of plastics.
Welding is the process of physically joining the chemically compatible components of two or more parts.
This is a very important process in order to guarantee the perfect union between them.
However, many variables must be taken into account when deciding to join several parts into a single object.
The union, even if perfect, is not enough in itself to guarantee a good result.
Physical, chemical and structural characteristics must also be taken into account.
The object must be joined so that it can maintain its shape, size and characteristics over time while being subject to the most varied external climatic and mechanical factors.
Moreover, the time available and any structural constraints must also be considered.
This is why at TFB we use different welding techniques.
We choose the most suitable technique for each part to be welded and for the customer’s needs.
We use the following techniques:

HOT PLATE WELDING

This welding technology creates the necessary plasticisation for perfectly joining the two parts to be welded using a heated plate.
This plate is thermo-regulated depending on the type of thermoplastic material to be welded.
Our welding machines guarantee that the part to be welded is perfectly housed in the jig, and allow even large components to be adequately welded.
By means of advanced operating force controls with value and process time management, we are also able to guarantee watertight and force-resistant welds.

ULTRASONIC WELDING

This welding technology joins materials being held together in contact using the rubbing created by the ultrasonic vibration, which generates the heat necessary for the fusion and welding of thermoplastic components.
This a fast and reliable welding technique.

VIBRATION WELDING

This welding technology is performed by direct contact between the two parts to be welded.
Thanks to rubbing with a certain degree of pressure, we can obtain fast and safe welds.
There are two main types of vibration welding machines. According to the morphological and structural characteristics of the part to be welded you can choose between:
Linear vibration welders
Orbital vibration welders

ROTARY FRICTION WELDING

In rotary friction welding, friction is created by the rotation of the rotating part which is adequately pressed against the part fixed in the jig.
The increase in temperature created by rubbing increases the temperature of the thermoplastic material, thus melting together the two parts coming into contact.
This welding technology is ideal for parts to be welded with circular welding track only.

INFRARED WELDING

Infrared welding is a non-contact welding technique, where infrared radiation rapidly heats the plastic and brings it to the right degree of plasticisation to perfectly melt and join together the parts to be welded. The result is an extremely clean weld, which can also be used as a way to soften the part and get it ready for other types of welding.

LEAK TESTS

LEAK TESTS ARE CARRIED OUT TO CHECK THE TIGHTNESS OF THE WELDED AND PROCESSED PARTS.
THERE ARE POSITIVE PRESSURE TESTS AND NEGATIVE PRESSURE TESTS.

POSITIVE PRESSURE TESTS

These tests are used to verify the presence of pressure drops in the welded or assembled component, or the presence of pressure interactions in the case of several compartments joined together, in order to guarantee a perfect watertight weld.

NEGATIVE PRESSURE TESTS

These tests follow the same principle of positive pressure test; the only difference is that the system is placed under vacuum to check that there is no suction or interaction between the various sectors.

MOUNTING OF COMPONENTS AND CHECKS:

WE MANAGE MOUNTING OPERATIONS THROUGH PROCESS AUTOMATION.
WE ARRANGE THE RAPID AND CONTINUOUS MOUNTING OF VARIOUS COMPONENTS,
E.G.
BUSHINGS, GASKETS, O-RINGS, CLIPS, RUBBER COMPONENTS, SENSORS.
THESE AUTOMATIONS SIGNIFICANTLT REDUCE ASSEMBLY TIMES WHILE AVOIDING ANY ERRORS AT THIS IMPORTANT STAGE.
DEPENDING ON THE NEED, THERE ARE DIFFERENT TECHNIQUES FOR INSERTING EXTERNAL COMPONENTS INTO PLASTICS.

PRESSURE INSERTION

This type of insertion is used to insert auxiliary parts, such as bushings, centring devices, bearings, and aesthetic components.
The pressure applied must be calibrated and progressive to avoid damaging the part itself.

HEAT INSERTION       

This type of insertion uses the energy of heat, which can be radiated by contact or induction, to couple bushings, inserts, metal and non-metal spacers and other elements, with the plastic item.
Once the element has been inserted into the plastic item, calibration is carried out using a cold punch, and the value on the item is verified with centesimal resolution with great speed and precision.

ULTRASONIC INSERTION

This is done by means of mechanical vibrations transmitted by a sonotrode.
Friction is created thanks to the vibration transmitted by the sonotrode to the item. Such friction allows the item to reach a certain temperature and an appropriate plasticity to accept the inserted element.
Once cooled, the element will be firmly joined to the plastic item in case of different materials, or welded in case of compatible bonding plastics.

INSERTION BY SCREWING

We offer screwing systems for every requirement in industrial assembly:
from stationary systems with torque arms and positioning systems, to in-line integrated screwing systems managed automatically by robots with screw shooting interlocking system.
Thanks to various types of screwdrivers with torque and angle control, we are able to meet all our customers’ needs.

RIVETING

Riveting is a technique used to join compatible and non-compatible thermoplastic materials, or to join different materials together.
There are various riveting techniques that can be used depending on the characteristics and needs of the pieces to be joined.
The most commonly used systems are:

COLD RIVETING

This technique is carried out by pressure. The rivet inserted between the two parts is upset at one end, i.e. deformed to create a new head on the other hand.

HOT RIVETING

In this case, heat is transmitted by direct, indirect or pulsed induction, by a hot air jet or by heat conduction transmitted by a hot bar or a thermode.
This heat creates sufficient plasticity to deform the rivet and give it the desired head shape by applying pressure.
Once it has cooled, pressure is released, thus ensuring a good tightness on the piece.

ULTRASONIC RIVETING

The part is heated up by friction thanks to the mechanical vibrations generated by a sonotrode.
The sonotrode or pulse transmitter will have the shape of the head that you want to give to the rivet.
Once plasticity has been reached, we obtain the desired effect by applying the right pressure.
Once it has cooled, pressure is released, thus ensuring a good tightness on the piece.
It is an excellent solution when hot riveting with faster process times is required.

INSERTION OF AUXILIARY ELEMENTS USING SPECIAL GRIPPERS

We specialise in the insertion of auxiliary elements into moulded parts.
We can insert gaskets or O-rings on a bore or stem using special grippers and technologically advanced systems.
We offer systems designed and mounted on operator workbenches, or mounted in-line and fully robot-assisted.

CONTROL SYSTEMS

We use several control systems to check that all processes have been carried out correctly and to ensure perfect repeatability with no errors.
Our control systems include: presence and position checks, dimensional testing using a range of non-contact detection systems, vision systems, and three-dimensional testing.

TOOLING

CUTTING

The cutting of plastics can be carried out using various techniques and types of tool.
The following techniques are generally used depending on the type of cut required and the type of material to be cut.

BLADE/GUILLOTINE CUTTING

A special blade is used for this cutting technique. The result is a clean cut that produces no chips or swarf.
The cut can be orthogonal or angled with a fair tolerance of flatness.

ORBITAL CUTTING WITH SPECIAL CURVED BLADE AND WITHOUT CHIP REMOVAL

A special curved blade is used for this cutting technique. Its particular shape is perfect for performing cuts on curved surfaces, on pipes, and wherever a clean cut is required together with small increase in the temperature of the thermoplastic component and without any chips or dust deriving from the process.

CUTTING WITH CIRCULAR SAW

This cutting technique is used for performing linear cuts in sheets, pipes, etc.
It is a simple technology to obtain perfectly linear cuts while using different types of blades.

DIE-CUTTING

This technique is used when complex and repetitive cuts must be performed.
The quality of the cut performed is very precise.

MILLING

Milling is a cutting process in which material is removed using a dedicated rotating tool (cutter) supported by a spindle, so as to transform raw material into a finished object.
A wide range of cutting tools with different sizes and profile shapes are available and can be used depending on the type of machining required and the material to be removed to achieve the desired machining operations.
The most common milling processes on plastics are the following: roughing, finishing, drilling, boring.
TFB uses multi-axis CNC milling machines. This allows you to manage all operations and values directly from the panel, and to manage all geometric shapes and operations with absolute precision thanks to dedicated tools.

BORING

This is a mechanical operation that is done to correct small differences in axiality and diameter of holes.
Such operation requires extreme precision.
This is why we at TFB use a CNC boring machine. This allows you to manage all operations and values directly from the panel, and to manage all geometric shapes and operations with absolute precision thanks to dedicated tools.

DRILLING

Depending on the material to be drilled, there are different structural characteristics to be taken into account.
Incorrect drilling may cause overheating and deformation, small cracks, or break the piece itself.
Different cleaning requirements are present when drilling, depending on the customer’s requirements and where the piece being processed will be placed. There are in fact several drilling techniques that must be carefully considered, such as traditional drilling by chip removal or drilling without chips.
With this latter technique, drilling can be performed without producing waste material or contaminating the piece, while avoiding cleaning cycles and saving time and costs.

BLANKING

Blanking is used to cut parts of thermoplastic materials.
It is carried out using a punch and a die.
When the punch comes into contact with the material to be cut, it pushes it against the die with a force that is mechanically impressed in various ways depending on the characteristics of the cut and the material.
At this point, the material pushed by the punch into the die reaches the breaking point and is cut.
The clearance between the punch and the die must be perfectly calibrated in order to obtain a clean and precise cut.

PUNCHING

Punching is carried out using a special tool. This technique is mainly used to engrave or mark a thermoplastic piece.

DEBURRING

This is done to remove any burrs from the plastic materials and imperfections on the machined piece, usually deriving from excessive melting caused by overheating of the plastic materials subjected to tooling, such as
cutting, drilling, milling, welding.
Deburring can be carried out by means of a tool (therefore by removal) or by means of a jet of hot air in thermal reduction (therefore by fusion).

CLEANING

Cleaning of plastic materials is carried out to remove swarf or other types of dirt from inside the plastic details created through machining operations performed on them.
The electrostatic charge that forms inside keeps these impurities that could become very dangerous if not removed.
We are able to neutralise the electrostatic charge and remove all impurities using ionised air blowing systems, air washing and other technologies combined with a suction system and a special micro-vibration system.
We design tailor-made systems for each need, depending on the requirements of the material to be processed.
In addition to blowing and washing, we can also offer cleaning in pressurised dust-free environments.

TESTS – QUALITY AND MORPHOLOGY CHECKS

TESTS AND CHECKS ARE FUNDAMENTAL AND NECESSARY PHASES IN ANY PRODUCTION INDUSTRY.
DON’T LET YOUR CUSTOMERS DEAL WITH SUCH PHASES. IT IS EASIER TO FIX A PRODUCTION ERROR THAN TO REVERSE A BAD IMPRESSION.
AT TFB WE SPECIALISE IN ALL TYPES OF CHECKS AND WE USE THE FOLLOWING TECHNOLOGIES DEPENDING ON YOUR NEEDS.

LEAK TESTS

Leak tests are carried out to check the tightness of the welded and processed parts.
There are positive pressure tests and negative pressure tests

POSITIVE PRESSURE TESTS

Questi test, servono per verficare che non ci siano perdite di pressioni esterne, o interazioni di pressioni, in caso in cui ci siano più vani uniti tra loro, nei quali si potrebbe formare un interscambio di pressioni, senza necessariamente avere una perdita.

TEST IN PRESSIONE POSITIVA

These tests are used to verify the presence of external pressure drops, or the presence of pressure interactions in the case of several compartments joined together, where an interchange of pressures could form without necessarily having a leak.

NEGATIVE PRESSURE TESTS

These tests follow the same principle of positive pressure test; the only difference is that the system is placed under vacuum to check that there is no suction or interaction between the various sectors.
We can guarantee smooth and repeatable production only when we are sure that the dimensions and all the components making up the object to be examined are in order, and that nothing is missing.

QUALITY AND DIMENSIONAL TESTS

They are very important to ensure the continuity of the products being processed.
They are performed to check the shape, colour and size of the piece.
We use the most innovative control systems to guarantee the correct morphology of the pieces to be analysed.
Thanks to these checks we speed up production processes without incurring risks.
The checks are manifold and can be on:
shape, colour, geometry, weight, thickness, distance between the various components, presence of correct holes; three-dimensional checks of the piece (even of large dimensions) are also available.

FLOW TESTS

They are carried out to check the flow rate of air and/or liquids inside a passage.
They are carried out to check that the moulded or machined part does not have any obstructions or slowdowns to the flow.
Different systems can be used for flow tests depending on what is being tested.

HANDLING

It is important to ensure the correct flow between the various production stages. This can be summarised with great clarity in a few words:
greater precision, speed, power and repeatability.
The aim is to reduce human intervention to a minimum, thus lowering costs, increasing production, and minimising errors.
With the help of the most modern technologies, we can use the best handling system depending on the requirements.
At Tfb we offer conveyor lines, rotary tables, gripping systems, robots (Cartesian robots, cobots, anthropomorphic robots, SCARAs).
We provide all the flexibility needed to guarantee increases in production where greater speed in interchange is required.
It is therefore important to design handling lines able to evolve in terms of speed, power and rapid changeover of settings and layouts.

 MARKING

This is a mandatory technology for all products for which there is an EU directive.
TfB manufactures marking systems with different technologies applied depending on the customer’s requirements and the product to be marked.
We use the following technologies:
micro-percussion marking, laser marking, thermal transfer marking.

MICRO-PERCUSSION MARKING

It carries out engraving without the addition of material.
A punch made of high-frequency vibrating carbide is electronically controlled in order to engrave on the product to be marked.
The micro-punch can be electromagnetic or pneumatic. It can be used on flat and non-flat surfaces.

LASER MARKING

This type of marking is done without contact. Marking is done by heat from a laser beam.
It is a highly precise marking that is fast and adaptable to every need.
It includes the following: engraving, selective removal, colour change, annealing, and foaming.
It creates high-level marks that are highly resistant to scratches and corrosion.

THERMAL TRANSFER MARKING

This technology is an ideal solution for transmitting high-resolution variable data.
It does not require ink and therefore any drying time. It is very performing on uneven and particularly hard surfaces.
It creates a very durable, fast, flexible, but above all easy-to-handle marking.
This makes it suitable for all types of production.

INKJET MARKING

Inkjet marking can be used for marking various products.
It is a fast, safe and very flexible marking method.
Using a special high-pressure pump, a microscopic nozzle, an acoustic wave and an electrostatic field, we create a flow of liquid that can vary between 60,000 and 160,000 drops per second.
In addition, we can use different types of ink, depending on the field of application (mechanics, food, etc).

PAD PRINTING

Pad printing is a printing process that makes it possible to print marks, logos and lettering on any type of object, even on surfaces with irregular, concave or convex shapes.
This type of marking allows any type of nuance or effect to be transferred to the object with great precision.
Perfect adaptation to the piece is achieved thanks to the malleability and pliability of the pads.
Marking can also be done with several colours.
This is an economical technology given the low ink consumption.

TRACEABILITY AND TRACKING IN INDUSTRY

Here below we’ll explain you why traceability plays such an important role in Industry 4.0.
The evolution of processes in terms of qualitative productivity is only possible if we are able to monitor each process.
Identification is based on the recognition through monitoring and recording of the activities carried out.
TFB develops tailor-made solutions to make your production phases safe and smooth.
With the help of reading visual systems or tags, and terminals for the identification of production and processing stages, we can gain total control on them with the real-time identification of issues in the production chain.
So, it’s not only about quality control. It’s about immediately identifying weaknesses in the production process.
Controlled production is successful production.

We specialise in the production of multifunctional machines with interchangeable jigs,
with one or more stations, for all the processing required after blow moulding.

DEFLASHING:

This technique is used to eliminate the excess material (flash) that forms during the blowing phase.
At Tfb we produce finishing lines parallel to the moulding phase and in-line with special machines for deflashing, as well as multifunctional stations where it is possible to carry out several operations simultaneously in a flexible manner thanks to interchangeable jigs (deflashing, cutting, drilling, welding), thus optimising machine cycle times.
We can perform as many operations as possible during the blowing cycle, thus minimising processing time.

POST-COOLING MACHINES

We produce special post-cooling machines for cooling freshly moulded parts, using water and air technologies and interchangeable jigs.
Cooling can be in two ways depending on requirements.

Water cooling

This is done by immersing the freshly hot-moulded part in thermo-regulated water simultaneously with the blowing cycle.
The part is suitably fixed to a clamping jig and then immersed in water. The thermal shock cools the part in a short time, bringing it back to the correct structural and dimensional characteristics. Otherwise, the still warm part would undergo dimensional changes due to shrinkage.
The water temperature and soaking time may vary depending on the chemical and structural characteristics of the part to be cooled.

Air cooling

This is done by cooling with cold or ambient air.
The still-warm moulded part is fixed to a clamping jig which is placed into a special cooling cabinet. The right amount of cold air is then injected inside this cabinet.
This operation allows the part to cool while maintaining its structural and dimensional characteristics.

WELDING

We specialise in the welding of plastics.
Welding is the process of physically joining the chemically compatible components of two or more parts.
This is a very important process in order to guarantee the perfect union between them.
However, many variables must be taken into account when deciding to join several parts into a single object.
The union, even if perfect, is not enough in itself to guarantee a good result.
Physical, chemical and structural characteristics must also be taken into account.
The object must be joined so that it can maintain its shape, size and characteristics over time while being subject to the most varied external climatic and mechanical factors.
Moreover, the time available and any structural constraints must also be considered.
This is why at TFB we use different welding techniques.
We choose the most suitable technique for each part to be welded and for the customer’s needs.
We use the following techniques:

HOT PLATE WELDING

This welding technology creates the necessary plasticisation for perfectly joining the two parts to be welded using a heated plate.
This plate is thermo-regulated depending on the type of thermoplastic material to be welded.
Our welding machines guarantee that the part to be welded is perfectly housed in the jig, and allow even large components to be adequately welded.
By means of advanced operating force controls with value and process time management, we are also able to guarantee watertight and force-resistant welds.

ULTRASONIC WELDING

This welding technology joins materials being held together in contact using the rubbing created by the ultrasonic vibration, which generates the heat necessary for the fusion and welding of thermoplastic components.
This a fast and reliable welding technique.

VIBRATION WELDING

This welding technology is performed by direct contact between the two parts to be welded.
Thanks to rubbing with a certain degree of pressure, we can obtain fast and safe welds.
There are two main types of vibration welding machines. According to the morphological and structural characteristics of the part to be welded you can choose between:
Linear vibration welders
Orbital vibration welders

ROTARY FRICTION WELDING

In rotary friction welding, friction is created by the rotation of the rotating part which is adequately pressed against the part fixed in the jig.
The increase in temperature created by rubbing increases the temperature of the thermoplastic material, thus melting together the two parts coming into contact.
This welding technology is ideal for parts to be welded with circular welding track only.

INFRARED WELDING

Infrared welding is a non-contact welding technique, where infrared radiation rapidly heats the plastic and brings it to the right degree of plasticisation to perfectly melt and join together the parts to be welded. The result is an extremely clean weld, which can also be used as a way to soften the part and get it ready for other types of welding.

LEAK TESTS

LEAK TESTS ARE CARRIED OUT TO CHECK THE TIGHTNESS OF THE WELDED AND PROCESSED PARTS.
THERE ARE POSITIVE PRESSURE TESTS AND NEGATIVE PRESSURE TESTS.

POSITIVE PRESSURE TESTS

These tests are used to verify the presence of pressure drops in the welded or assembled component, or the presence of pressure interactions in the case of several compartments joined together, in order to guarantee a perfect watertight weld.

NEGATIVE PRESSURE TESTS

These tests follow the same principle of positive pressure test; the only difference is that the system is placed under vacuum to check that there is no suction or interaction between the various sectors.

MOUNTING OF COMPONENTS AND CHECKS:

WE MANAGE MOUNTING OPERATIONS THROUGH PROCESS AUTOMATION.
WE ARRANGE THE RAPID AND CONTINUOUS MOUNTING OF VARIOUS COMPONENTS,
E.G.
BUSHINGS, GASKETS, O-RINGS, CLIPS, RUBBER COMPONENTS, SENSORS.
THESE AUTOMATIONS SIGNIFICANTLT REDUCE ASSEMBLY TIMES WHILE AVOIDING ANY ERRORS AT THIS IMPORTANT STAGE.
DEPENDING ON THE NEED, THERE ARE DIFFERENT TECHNIQUES FOR INSERTING EXTERNAL COMPONENTS INTO PLASTICS.

PRESSURE INSERTION

This type of insertion is used to insert auxiliary parts, such as bushings, centring devices, bearings, and aesthetic components.
The pressure applied must be calibrated and progressive to avoid damaging the part itself.

HEAT INSERTION       

This type of insertion uses the energy of heat, which can be radiated by contact or induction, to couple bushings, inserts, metal and non-metal spacers and other elements, with the plastic item.
Once the element has been inserted into the plastic item, calibration is carried out using a cold punch, and the value on the item is verified with centesimal resolution with great speed and precision.

ULTRASONIC INSERTION

This is done by means of mechanical vibrations transmitted by a sonotrode.
Friction is created thanks to the vibration transmitted by the sonotrode to the item. Such friction allows the item to reach a certain temperature and an appropriate plasticity to accept the inserted element.
Once cooled, the element will be firmly joined to the plastic item in case of different materials, or welded in case of compatible bonding plastics.

INSERTION BY SCREWING

We offer screwing systems for every requirement in industrial assembly:
from stationary systems with torque arms and positioning systems, to in-line integrated screwing systems managed automatically by robots with screw shooting interlocking system.
Thanks to various types of screwdrivers with torque and angle control, we are able to meet all our customers’ needs.

RIVETING

Riveting is a technique used to join compatible and non-compatible thermoplastic materials, or to join different materials together.
There are various riveting techniques that can be used depending on the characteristics and needs of the pieces to be joined.
The most commonly used systems are:

COLD RIVETING

This technique is carried out by pressure. The rivet inserted between the two parts is upset at one end, i.e. deformed to create a new head on the other hand.

HOT RIVETING

In this case, heat is transmitted by direct, indirect or pulsed induction, by a hot air jet or by heat conduction transmitted by a hot bar or a thermode.
This heat creates sufficient plasticity to deform the rivet and give it the desired head shape by applying pressure.
Once it has cooled, pressure is released, thus ensuring a good tightness on the piece.

ULTRASONIC RIVETING

The part is heated up by friction thanks to the mechanical vibrations generated by a sonotrode.
The sonotrode or pulse transmitter will have the shape of the head that you want to give to the rivet.
Once plasticity has been reached, we obtain the desired effect by applying the right pressure.
Once it has cooled, pressure is released, thus ensuring a good tightness on the piece.
It is an excellent solution when hot riveting with faster process times is required.

INSERTION OF AUXILIARY ELEMENTS USING SPECIAL GRIPPERS

We specialise in the insertion of auxiliary elements into moulded parts.
We can insert gaskets or O-rings on a bore or stem using special grippers and technologically advanced systems.
We offer systems designed and mounted on operator workbenches, or mounted in-line and fully robot-assisted.

CONTROL SYSTEMS

We use several control systems to check that all processes have been carried out correctly and to ensure perfect repeatability with no errors.
Our control systems include: presence and position checks, dimensional testing using a range of non-contact detection systems, vision systems, and three-dimensional testing.

TOOLING

CUTTING

The cutting of plastics can be carried out using various techniques and types of tool.
The following techniques are generally used depending on the type of cut required and the type of material to be cut.

BLADE/GUILLOTINE CUTTING

A special blade is used for this cutting technique. The result is a clean cut that produces no chips or swarf.
The cut can be orthogonal or angled with a fair tolerance of flatness.

ORBITAL CUTTING WITH SPECIAL CURVED BLADE AND WITHOUT CHIP REMOVAL

A special curved blade is used for this cutting technique. Its particular shape is perfect for performing cuts on curved surfaces, on pipes, and wherever a clean cut is required together with small increase in the temperature of the thermoplastic component and without any chips or dust deriving from the process.

CUTTING WITH CIRCULAR SAW

This cutting technique is used for performing linear cuts in sheets, pipes, etc.
It is a simple technology to obtain perfectly linear cuts while using different types of blades.

DIE-CUTTING

This technique is used when complex and repetitive cuts must be performed.
The quality of the cut performed is very precise.

MILLING

Milling is a cutting process in which material is removed using a dedicated rotating tool (cutter) supported by a spindle, so as to transform raw material into a finished object.
A wide range of cutting tools with different sizes and profile shapes are available and can be used depending on the type of machining required and the material to be removed to achieve the desired machining operations.
The most common milling processes on plastics are the following: roughing, finishing, drilling, boring.
TFB uses multi-axis CNC milling machines. This allows you to manage all operations and values directly from the panel, and to manage all geometric shapes and operations with absolute precision thanks to dedicated tools.

BORING

This is a mechanical operation that is done to correct small differences in axiality and diameter of holes.
Such operation requires extreme precision.
This is why we at TFB use a CNC boring machine. This allows you to manage all operations and values directly from the panel, and to manage all geometric shapes and operations with absolute precision thanks to dedicated tools.

DRILLING

Depending on the material to be drilled, there are different structural characteristics to be taken into account.
Incorrect drilling may cause overheating and deformation, small cracks, or break the piece itself.
Different cleaning requirements are present when drilling, depending on the customer’s requirements and where the piece being processed will be placed. There are in fact several drilling techniques that must be carefully considered, such as traditional drilling by chip removal or drilling without chips.
With this latter technique, drilling can be performed without producing waste material or contaminating the piece, while avoiding cleaning cycles and saving time and costs.

BLANKING

Blanking is used to cut parts of thermoplastic materials.
It is carried out using a punch and a die.
When the punch comes into contact with the material to be cut, it pushes it against the die with a force that is mechanically impressed in various ways depending on the characteristics of the cut and the material.
At this point, the material pushed by the punch into the die reaches the breaking point and is cut.
The clearance between the punch and the die must be perfectly calibrated in order to obtain a clean and precise cut.

PUNCHING

Punching is carried out using a special tool. This technique is mainly used to engrave or mark a thermoplastic piece.

DEBURRING

This is done to remove any burrs from the plastic materials and imperfections on the machined piece, usually deriving from excessive melting caused by overheating of the plastic materials subjected to tooling, such as
cutting, drilling, milling, welding.
Deburring can be carried out by means of a tool (therefore by removal) or by means of a jet of hot air in thermal reduction (therefore by fusion).

CLEANING

Cleaning of plastic materials is carried out to remove swarf or other types of dirt from inside the plastic details created through machining operations performed on them.
The electrostatic charge that forms inside keeps these impurities that could become very dangerous if not removed.
We are able to neutralise the electrostatic charge and remove all impurities using ionised air blowing systems, air washing and other technologies combined with a suction system and a special micro-vibration system.
We design tailor-made systems for each need, depending on the requirements of the material to be processed.
In addition to blowing and washing, we can also offer cleaning in pressurised dust-free environments.

TESTS – QUALITY AND MORPHOLOGY CHECKS

TESTS AND CHECKS ARE FUNDAMENTAL AND NECESSARY PHASES IN ANY PRODUCTION INDUSTRY.
DON’T LET YOUR CUSTOMERS DEAL WITH SUCH PHASES. IT IS EASIER TO FIX A PRODUCTION ERROR THAN TO REVERSE A BAD IMPRESSION.
AT TFB WE SPECIALISE IN ALL TYPES OF CHECKS AND WE USE THE FOLLOWING TECHNOLOGIES DEPENDING ON YOUR NEEDS.

LEAK TESTS

Leak tests are carried out to check the tightness of the welded and processed parts.
There are positive pressure tests and negative pressure tests

POSITIVE PRESSURE TESTS

Questi test, servono per verficare che non ci siano perdite di pressioni esterne, o interazioni di pressioni, in caso in cui ci siano più vani uniti tra loro, nei quali si potrebbe formare un interscambio di pressioni, senza necessariamente avere una perdita.

TEST IN PRESSIONE POSITIVA

These tests are used to verify the presence of external pressure drops, or the presence of pressure interactions in the case of several compartments joined together, where an interchange of pressures could form without necessarily having a leak.

NEGATIVE PRESSURE TESTS

These tests follow the same principle of positive pressure test; the only difference is that the system is placed under vacuum to check that there is no suction or interaction between the various sectors.
We can guarantee smooth and repeatable production only when we are sure that the dimensions and all the components making up the object to be examined are in order, and that nothing is missing.

QUALITY AND DIMENSIONAL TESTS

They are very important to ensure the continuity of the products being processed.
They are performed to check the shape, colour and size of the piece.
We use the most innovative control systems to guarantee the correct morphology of the pieces to be analysed.
Thanks to these checks we speed up production processes without incurring risks.
The checks are manifold and can be on:
shape, colour, geometry, weight, thickness, distance between the various components, presence of correct holes; three-dimensional checks of the piece (even of large dimensions) are also available.

FLOW TESTS

They are carried out to check the flow rate of air and/or liquids inside a passage.
They are carried out to check that the moulded or machined part does not have any obstructions or slowdowns to the flow.
Different systems can be used for flow tests depending on what is being tested.

HANDLING

It is important to ensure the correct flow between the various production stages. This can be summarised with great clarity in a few words:
greater precision, speed, power and repeatability.
The aim is to reduce human intervention to a minimum, thus lowering costs, increasing production, and minimising errors.
With the help of the most modern technologies, we can use the best handling system depending on the requirements.
At Tfb we offer conveyor lines, rotary tables, gripping systems, robots (Cartesian robots, cobots, anthropomorphic robots, SCARAs).
We provide all the flexibility needed to guarantee increases in production where greater speed in interchange is required.
It is therefore important to design handling lines able to evolve in terms of speed, power and rapid changeover of settings and layouts.

 MARKING

This is a mandatory technology for all products for which there is an EU directive.
TfB manufactures marking systems with different technologies applied depending on the customer’s requirements and the product to be marked.
We use the following technologies:
micro-percussion marking, laser marking, thermal transfer marking.

MICRO-PERCUSSION MARKING

It carries out engraving without the addition of material.
A punch made of high-frequency vibrating carbide is electronically controlled in order to engrave on the product to be marked.
The micro-punch can be electromagnetic or pneumatic. It can be used on flat and non-flat surfaces.

LASER MARKING

This type of marking is done without contact. Marking is done by heat from a laser beam.
It is a highly precise marking that is fast and adaptable to every need.
It includes the following: engraving, selective removal, colour change, annealing, and foaming.
It creates high-level marks that are highly resistant to scratches and corrosion.

THERMAL TRANSFER MARKING

This technology is an ideal solution for transmitting high-resolution variable data.
It does not require ink and therefore any drying time. It is very performing on uneven and particularly hard surfaces.
It creates a very durable, fast, flexible, but above all easy-to-handle marking.
This makes it suitable for all types of production.

INKJET MARKING

Inkjet marking can be used for marking various products.
It is a fast, safe and very flexible marking method.
Using a special high-pressure pump, a microscopic nozzle, an acoustic wave and an electrostatic field, we create a flow of liquid that can vary between 60,000 and 160,000 drops per second.
In addition, we can use different types of ink, depending on the field of application (mechanics, food, etc).

PAD PRINTING

Pad printing is a printing process that makes it possible to print marks, logos and lettering on any type of object, even on surfaces with irregular, concave or convex shapes.
This type of marking allows any type of nuance or effect to be transferred to the object with great precision.
Perfect adaptation to the piece is achieved thanks to the malleability and pliability of the pads.
Marking can also be done with several colours.
This is an economical technology given the low ink consumption.

TRACEABILITY AND TRACKING IN INDUSTRY

Here below we’ll explain you why traceability plays such an important role in Industry 4.0.
The evolution of processes in terms of qualitative productivity is only possible if we are able to monitor each process.
Identification is based on the recognition through monitoring and recording of the activities carried out.
TFB develops tailor-made solutions to make your production phases safe and smooth.
With the help of reading visual systems or tags, and terminals for the identification of production and processing stages, we can gain total control on them with the real-time identification of issues in the production chain.
So, it’s not only about quality control. It’s about immediately identifying weaknesses in the production process.
Controlled production is successful production.

This moulding technique is used for thermoplastic materials and allows to obtain hollow bodies of different sizes and shapes with high thicknesses. It is suitable for the production of small series of complex items and of internally hollow items that cannot be obtained otherwise. It is also very suitable for the production of large items, such as containers, tanks, taking advantage of the possibility to immediately obtain hollow products without subsequent welding phases.

At Tfb we specialise in handling all the requirements of moulded pieces using rotational moulding technology. At Tfb we offer automatic systems, special machines with interchangeable equipment to meet all processing requirements. Moreover, we completely manage the handling and traceability phases as well as all the necessary tests to guarantee correct processing:

WELDING

We specialise in the welding of plastics.
Welding is the process of physically joining the chemically compatible components of two or more parts.
This is a very important process in order to guarantee the perfect union between them.
However, many variables must be taken into account when deciding to join several parts into a single object.
The union, even if perfect, is not enough in itself to guarantee a good result.
Physical, chemical and structural characteristics must also be taken into account.
The object must be joined so that it can maintain its shape, size and characteristics over time while being subject to the most varied external climatic and mechanical factors.
Moreover, the time available and any structural constraints must also be considered.
This is why at TFB we use different welding techniques.
We choose the most suitable technique for each part to be welded and for the customer’s needs.
We use the following techniques:

HOT PLATE WELDING

This welding technology creates the necessary plasticisation for perfectly joining the two parts to be welded using a heated plate.
This plate is thermo-regulated depending on the type of thermoplastic material to be welded.
Our welding machines guarantee that the part to be welded is perfectly housed in the jig, and allow even large components to be adequately welded.
By means of advanced operating force controls with value and process time management, we are also able to guarantee watertight and force-resistant welds.

ULTRASONIC WELDING

This welding technology joins materials being held together in contact using the rubbing created by the ultrasonic vibration, which generates the heat necessary for the fusion and welding of thermoplastic components.
This a fast and reliable welding technique.

VIBRATION WELDING

This welding technology is performed by direct contact between the two parts to be welded.
Thanks to rubbing with a certain degree of pressure, we can obtain fast and safe welds.
There are two main types of vibration welding machines. According to the morphological and structural characteristics of the part to be welded you can choose between:
Linear vibration welders
Orbital vibration welders

ROTARY FRICTION WELDING

In rotary friction welding, friction is created by the rotation of the rotating part which is adequately pressed against the part fixed in the jig.
The increase in temperature created by rubbing increases the temperature of the thermoplastic material, thus melting together the two parts coming into contact.
This welding technology is ideal for parts to be welded with circular welding track only.

INFRARED WELDING

Infrared welding is a non-contact welding technique, where infrared radiation rapidly heats the plastic and brings it to the right degree of plasticisation to perfectly melt and join together the parts to be welded. The result is an extremely clean weld, which can also be used as a way to soften the part and get it ready for other types of welding.

LEAK TESTS

LEAK TESTS ARE CARRIED OUT TO CHECK THE TIGHTNESS OF THE WELDED AND PROCESSED PARTS.
THERE ARE POSITIVE PRESSURE TESTS AND NEGATIVE PRESSURE TESTS.

POSITIVE PRESSURE TESTS

These tests are used to verify the presence of pressure drops in the welded or assembled component, or the presence of pressure interactions in the case of several compartments joined together, in order to guarantee a perfect watertight weld.

NEGATIVE PRESSURE TESTS

These tests follow the same principle of positive pressure test; the only difference is that the system is placed under vacuum to check that there is no suction or interaction between the various sectors.

MOUNTING OF COMPONENTS AND CHECKS:

WE MANAGE MOUNTING OPERATIONS THROUGH PROCESS AUTOMATION.
WE ARRANGE THE RAPID AND CONTINUOUS MOUNTING OF VARIOUS COMPONENTS,
E.G.
BUSHINGS, GASKETS, O-RINGS, CLIPS, RUBBER COMPONENTS, SENSORS.
THESE AUTOMATIONS SIGNIFICANTLT REDUCE ASSEMBLY TIMES WHILE AVOIDING ANY ERRORS AT THIS IMPORTANT STAGE.
DEPENDING ON THE NEED, THERE ARE DIFFERENT TECHNIQUES FOR INSERTING EXTERNAL COMPONENTS INTO PLASTICS.

PRESSURE INSERTION

This type of insertion is used to insert auxiliary parts, such as bushings, centring devices, bearings, and aesthetic components.
The pressure applied must be calibrated and progressive to avoid damaging the part itself.

HEAT INSERTION       

This type of insertion uses the energy of heat, which can be radiated by contact or induction, to couple bushings, inserts, metal and non-metal spacers and other elements, with the plastic item.
Once the element has been inserted into the plastic item, calibration is carried out using a cold punch, and the value on the item is verified with centesimal resolution with great speed and precision.

ULTRASONIC INSERTION

This is done by means of mechanical vibrations transmitted by a sonotrode.
Friction is created thanks to the vibration transmitted by the sonotrode to the item. Such friction allows the item to reach a certain temperature and an appropriate plasticity to accept the inserted element.
Once cooled, the element will be firmly joined to the plastic item in case of different materials, or welded in case of compatible bonding plastics.

INSERTION BY SCREWING

We offer screwing systems for every requirement in industrial assembly:
from stationary systems with torque arms and positioning systems, to in-line integrated screwing systems managed automatically by robots with screw shooting interlocking system.
Thanks to various types of screwdrivers with torque and angle control, we are able to meet all our customers’ needs.

RIVETING

Riveting is a technique used to join compatible and non-compatible thermoplastic materials, or to join different materials together.
There are various riveting techniques that can be used depending on the characteristics and needs of the pieces to be joined.
The most commonly used systems are:

COLD RIVETING

This technique is carried out by pressure. The rivet inserted between the two parts is upset at one end, i.e. deformed to create a new head on the other hand.

HOT RIVETING

In this case, heat is transmitted by direct, indirect or pulsed induction, by a hot air jet or by heat conduction transmitted by a hot bar or a thermode.
This heat creates sufficient plasticity to deform the rivet and give it the desired head shape by applying pressure.
Once it has cooled, pressure is released, thus ensuring a good tightness on the piece.

ULTRASONIC RIVETING

The part is heated up by friction thanks to the mechanical vibrations generated by a sonotrode.
The sonotrode or pulse transmitter will have the shape of the head that you want to give to the rivet.
Once plasticity has been reached, we obtain the desired effect by applying the right pressure.
Once it has cooled, pressure is released, thus ensuring a good tightness on the piece.
It is an excellent solution when hot riveting with faster process times is required.

INSERTION OF AUXILIARY ELEMENTS USING SPECIAL GRIPPERS

We specialise in the insertion of auxiliary elements into moulded parts.
We can insert gaskets or O-rings on a bore or stem using special grippers and technologically advanced systems.
We offer systems designed and mounted on operator workbenches, or mounted in-line and fully robot-assisted.

CONTROL SYSTEMS

We use several control systems to check that all processes have been carried out correctly and to ensure perfect repeatability with no errors.
Our control systems include: presence and position checks, dimensional testing using a range of non-contact detection systems, vision systems, and three-dimensional testing.

TOOLING

CUTTING

The cutting of plastics can be carried out using various techniques and types of tool.
The following techniques are generally used depending on the type of cut required and the type of material to be cut.

BLADE/GUILLOTINE CUTTING

A special blade is used for this cutting technique. The result is a clean cut that produces no chips or swarf.
The cut can be orthogonal or angled with a fair tolerance of flatness.

ORBITAL CUTTING WITH SPECIAL CURVED BLADE AND WITHOUT CHIP REMOVAL

A special curved blade is used for this cutting technique. Its particular shape is perfect for performing cuts on curved surfaces, on pipes, and wherever a clean cut is required together with small increase in the temperature of the thermoplastic component and without any chips or dust deriving from the process.

CUTTING WITH CIRCULAR SAW

This cutting technique is used for performing linear cuts in sheets, pipes, etc.
It is a simple technology to obtain perfectly linear cuts while using different types of blades.

DIE-CUTTING

This technique is used when complex and repetitive cuts must be performed.
The quality of the cut performed is very precise.

MILLING

Milling is a cutting process in which material is removed using a dedicated rotating tool (cutter) supported by a spindle, so as to transform raw material into a finished object.
A wide range of cutting tools with different sizes and profile shapes are available and can be used depending on the type of machining required and the material to be removed to achieve the desired machining operations.
The most common milling processes on plastics are the following: roughing, finishing, drilling, boring.
TFB uses multi-axis CNC milling machines. This allows you to manage all operations and values directly from the panel, and to manage all geometric shapes and operations with absolute precision thanks to dedicated tools.

BORING

This is a mechanical operation that is done to correct small differences in axiality and diameter of holes.
Such operation requires extreme precision.
This is why we at TFB use a CNC boring machine. This allows you to manage all operations and values directly from the panel, and to manage all geometric shapes and operations with absolute precision thanks to dedicated tools.

DRILLING

Depending on the material to be drilled, there are different structural characteristics to be taken into account.
Incorrect drilling may cause overheating and deformation, small cracks, or break the piece itself.
Different cleaning requirements are present when drilling, depending on the customer’s requirements and where the piece being processed will be placed. There are in fact several drilling techniques that must be carefully considered, such as traditional drilling by chip removal or drilling without chips.
With this latter technique, drilling can be performed without producing waste material or contaminating the piece, while avoiding cleaning cycles and saving time and costs.

BLANKING

Blanking is used to cut parts of thermoplastic materials.
It is carried out using a punch and a die.
When the punch comes into contact with the material to be cut, it pushes it against the die with a force that is mechanically impressed in various ways depending on the characteristics of the cut and the material.
At this point, the material pushed by the punch into the die reaches the breaking point and is cut.
The clearance between the punch and the die must be perfectly calibrated in order to obtain a clean and precise cut.

PUNCHING

Punching is carried out using a special tool. This technique is mainly used to engrave or mark a thermoplastic piece.

DEBURRING

This is done to remove any burrs from the plastic materials and imperfections on the machined piece, usually deriving from excessive melting caused by overheating of the plastic materials subjected to tooling, such as
cutting, drilling, milling, welding.
Deburring can be carried out by means of a tool (therefore by removal) or by means of a jet of hot air in thermal reduction (therefore by fusion).

CLEANING

Cleaning of plastic materials is carried out to remove swarf or other types of dirt from inside the plastic details created through machining operations performed on them.
The electrostatic charge that forms inside keeps these impurities that could become very dangerous if not removed.
We are able to neutralise the electrostatic charge and remove all impurities using ionised air blowing systems, air washing and other technologies combined with a suction system and a special micro-vibration system.
We design tailor-made systems for each need, depending on the requirements of the material to be processed.
In addition to blowing and washing, we can also offer cleaning in pressurised dust-free environments.

TESTS – QUALITY AND MORPHOLOGY CHECKS

TESTS AND CHECKS ARE FUNDAMENTAL AND NECESSARY PHASES IN ANY PRODUCTION INDUSTRY.
DON’T LET YOUR CUSTOMERS DEAL WITH SUCH PHASES. IT IS EASIER TO FIX A PRODUCTION ERROR THAN TO REVERSE A BAD IMPRESSION.
AT TFB WE SPECIALISE IN ALL TYPES OF CHECKS AND WE USE THE FOLLOWING TECHNOLOGIES DEPENDING ON YOUR NEEDS.

LEAK TESTS

Leak tests are carried out to check the tightness of the welded and processed parts.
There are positive pressure tests and negative pressure tests

POSITIVE PRESSURE TESTS

Questi test, servono per verficare che non ci siano perdite di pressioni esterne, o interazioni di pressioni, in caso in cui ci siano più vani uniti tra loro, nei quali si potrebbe formare un interscambio di pressioni, senza necessariamente avere una perdita.

TEST IN PRESSIONE POSITIVA

These tests are used to verify the presence of external pressure drops, or the presence of pressure interactions in the case of several compartments joined together, where an interchange of pressures could form without necessarily having a leak.

NEGATIVE PRESSURE TESTS

These tests follow the same principle of positive pressure test; the only difference is that the system is placed under vacuum to check that there is no suction or interaction between the various sectors.
We can guarantee smooth and repeatable production only when we are sure that the dimensions and all the components making up the object to be examined are in order, and that nothing is missing.

QUALITY AND DIMENSIONAL TESTS

They are very important to ensure the continuity of the products being processed.
They are performed to check the shape, colour and size of the piece.
We use the most innovative control systems to guarantee the correct morphology of the pieces to be analysed.
Thanks to these checks we speed up production processes without incurring risks.
The checks are manifold and can be on:
shape, colour, geometry, weight, thickness, distance between the various components, presence of correct holes; three-dimensional checks of the piece (even of large dimensions) are also available.

FLOW TESTS

They are carried out to check the flow rate of air and/or liquids inside a passage.
They are carried out to check that the moulded or machined part does not have any obstructions or slowdowns to the flow.
Different systems can be used for flow tests depending on what is being tested.

HANDLING

It is important to ensure the correct flow between the various production stages. This can be summarised with great clarity in a few words:
greater precision, speed, power and repeatability.
The aim is to reduce human intervention to a minimum, thus lowering costs, increasing production, and minimising errors.
With the help of the most modern technologies, we can use the best handling system depending on the requirements.
At Tfb we offer conveyor lines, rotary tables, gripping systems, robots (Cartesian robots, cobots, anthropomorphic robots, SCARAs).
We provide all the flexibility needed to guarantee increases in production where greater speed in interchange is required.
It is therefore important to design handling lines able to evolve in terms of speed, power and rapid changeover of settings and layouts.

 MARKING

This is a mandatory technology for all products for which there is an EU directive.
TfB manufactures marking systems with different technologies applied depending on the customer’s requirements and the product to be marked.
We use the following technologies:
micro-percussion marking, laser marking, thermal transfer marking.

MICRO-PERCUSSION MARKING

It carries out engraving without the addition of material.
A punch made of high-frequency vibrating carbide is electronically controlled in order to engrave on the product to be marked.
The micro-punch can be electromagnetic or pneumatic. It can be used on flat and non-flat surfaces.

LASER MARKING

This type of marking is done without contact. Marking is done by heat from a laser beam.
It is a highly precise marking that is fast and adaptable to every need.
It includes the following: engraving, selective removal, colour change, annealing, and foaming.
It creates high-level marks that are highly resistant to scratches and corrosion.

THERMAL TRANSFER MARKING

This technology is an ideal solution for transmitting high-resolution variable data.
It does not require ink and therefore any drying time. It is very performing on uneven and particularly hard surfaces.
It creates a very durable, fast, flexible, but above all easy-to-handle marking.
This makes it suitable for all types of production.

INKJET MARKING

Inkjet marking can be used for marking various products.
It is a fast, safe and very flexible marking method.
Using a special high-pressure pump, a microscopic nozzle, an acoustic wave and an electrostatic field, we create a flow of liquid that can vary between 60,000 and 160,000 drops per second.
In addition, we can use different types of ink, depending on the field of application (mechanics, food, etc).

PAD PRINTING

Pad printing is a printing process that makes it possible to print marks, logos and lettering on any type of object, even on surfaces with irregular, concave or convex shapes.
This type of marking allows any type of nuance or effect to be transferred to the object with great precision.
Perfect adaptation to the piece is achieved thanks to the malleability and pliability of the pads.
Marking can also be done with several colours.
This is an economical technology given the low ink consumption.

TRACEABILITY AND TRACKING IN INDUSTRY

Here below we’ll explain you why traceability plays such an important role in Industry 4.0.
The evolution of processes in terms of qualitative productivity is only possible if we are able to monitor each process.
Identification is based on the recognition through monitoring and recording of the activities carried out.
TFB develops tailor-made solutions to make your production phases safe and smooth.
With the help of reading visual systems or tags, and terminals for the identification of production and processing stages, we can gain total control on them with the real-time identification of issues in the production chain.
So, it’s not only about quality control. It’s about immediately identifying weaknesses in the production process.
Controlled production is successful production.

DO YOU NEED MORE INFORMATION?

Please contact us for more details.