EXTRUSION/INJECTION MOLDING

TP REFLEX GROUP has sixty-year experience in production of technical components of plastic materials and rubber, obtained through processes of molding and extrusion, in both mass production small serie, while paying a great deal of attention to the quality and the costs of our products.

The mold design is optimized in terms of both investment and further production requirements, from the pre-series production until the mass production. This is possible thanks to an integrated work of product and process engineers in our research and development center.

The mold design is supported by specialized software, for the solid modeling (3D CAD), the simulation of the molding process (moldflow analysis), and the integrated translation into work programs of machine tools which will construct the molds (CAD/CAM). Our knowledge, having designed and manufactured hundreds of molds, our experience, as primary users of mold for plastic injection, allow us to offer, as a reliable and specialized partner, turn-key solutions for producing plastic and rubber components.   

More in detail, TP REFLEX GROUP can manage the whole process of mold development and validation, from the initial analysis of the design of the product or component to be molded (determining possible critical issues and improvements in construction beforehand), to the stage of mold project validation, which is followed by the phase of construction and production. The process ends with the approval and validation of the mold, including the measuring report.

INJECTION MOLDING

The Group has more than 70 injection press machines, with increasing sizes from 25 ton to 1300 ton., both with horizontal and vertical structure, for plastics and rubber molding. Therefore, we can produce a wide range of plastic and rubber components, both for the sector of household appliances and other industries.

All factories have workshop for mold conditioning centralized systems for distribution of raw materials, with robots for unloading the components from the presses, with forming systems after molding, and viewing systems for quality control.

Each production unit is locally assisted by workshops dealing with maintenance for modification of molds and manufacturing equipment. The production of molded components is maintained at qualitative levels required by the customer and regulations, through statistical controls of size and function.

EXTRUSION

Blow-molding extrusion of corrugated hoses

The technology of blow-molding extrusion allows to create a wide range of extruded profiles both in terms of their internal/external diameter, and in terms of shape using appropriate molds. We can provide a wide range of standard extruded profiles and develop any customized profile according to the customer's specification. The extrusion lines are usually connected to robotized islands for cutting, forming of terminals, assembling, so to produce the finished product. We use mainly polypropylene as extrusion material, but for specific applications we can use dedicated materials (PP blend /rubber, …).
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Extrusion of multi-layer tubes

This extrusion technology allows to produce hoses with circular cross-section, consisting of one or more layers with the possibility of inserting a textile reinforcement between different layers. We produce single-layer tubes without reinforcement up to three layers with textile reinforcement. For specific applications we add an external metal reinforcement. The materials we usually employ are PVC, PE, PU, PEX. The extrusion lines are usually connected to the robotized islands for cutting, forming of terminals, assembling, so to produce the finished product.
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Extrusion of spiral tubes

This technology allows to produce hoses obtained through the laying of an extruded profile, generally in PVC or PU, in spiral form. The combination of different materials and extruded profiles makes it possible to create tubes with different features.
 In this respect we can add to the tube an internal layer with specific characteristics, such as e.g. a food-safe material or copper wire spirals to obtain electrostatic properties. We usually produce coiled tubes of a diameter from 16 to 200 mm, to be used for various applications and industries (transport of air, food industry, constructions …).

ELECTROMAGNETIC BOBBINS

TP REFLEX GROUP produces in house all the electromagnetic bobbins used as actuators in its products, completing all the assembly phases: from molding of plastic components to the winding, from arc welding of the fine copper wire on the terminals to the over-molding, from visual inspections with cameras to the high voltage functional test.

 Currently, TP REFLEX GROUP produces more than 30 million bobbins through automated lines for applications mainly related to the sector of household appliances, with different variants in terms of supply voltage (low voltage, 120V, 230V) and connection.