Savings are made on material, time and process parts when manufacturing e.g. heddles in the weaving industry, dental drills, anchor systems, ...

Result: starting from one wire diameter and by means of upsetting, creating all the parts in this one wire (such as an eye, a hook, a screw thread). For this reason all connecting and assembled parts are eliminated.

Research if a patent is possible: is the technology known somewhere and can the patent be obtained worldwide?

Result: the technology is not yet known. First a Belgian patent is obtained and afterwards the technology is also protected by a European patent. The patent protection is subsequently extended to countries with an interesting market segment such as Russia, China and the US.

Given that this technology is completely new and unknown, a knowledge platform must be set up.

Result: cooperation with an important West Flemish player who is interested in said technology. This includes the 3D construction using Solids and detail drawings to manufacture the parts. Elasticity tests are conducted on various materials such as carbon steel, INOX 316 and spring steel S75.

A joint decision is made to submit an R&D (research and development) application to the IWT (“Innovatie door Wetenschap en Technologie” = government agency for Innovation through Science and Technology). The application is approved.

This research substantiates the efficiency of the present patent technology. Meanwhile various applications have been developed. The project will be completed by June 2012 and has taken in total 3 years of research.

For the upsetting process Darvan uses a number of essential and specific technologies such as micro-milling, micro-wire erosion, sinker erosion, profile grinding and more.

See the following steps for the full explanation of the machining processes.

On a high-speed milling machine parts can be shaped in minute detail using micro-milling tools
(with a diameter smaller than 1 mm).

A precision wire spark erosion machine enables us to shape parts of up to 80 mm high to a precision of up to 0.002 mm with a roughness of 0.15 µm Ra using a wire diameter of up to a minimum of 0.03 mm.

With a micro-mould sinker spark erosion machine the shape is maintained and there is only nanowear. The machining process is highly precise and smoother surfaces are achieved.

Step 1. The profile to be shaped is cut in stone. This is used to make cutting profiles in stamps for instance.

Step 2. With this grinding technology a previously designed profile is followed whereby the smallest possible grinding radius
is 0.015 mm.

in function of the execution of various movements.

In addition this technology is included in the development. This means that complex mould movements in the flat surface can be achieved. Consequently complex mould parts and adjustments required in the course of the project can be made in a less complex manner.

An optimized roof tile is lighter than a stone roof tile. A system replacing roof hooks is incorporated in the tile. In combination with a heat pump the roof tile is able to heat the house. Furthermore it provides an aesthetically appealing solar cell system which integrates solar cell cooling.

Research how the innovations in the roof tile can be patented.

Result: the connection between two solar roof tiles is achieved by means of a mechanical connection system that is patented.

Darvan takes all the initiatives and looks for connections who are able to carry out an efficient execution
(e.g. Sirris, VKC, Plastic Vision).

The design is illustrated by means of a 3D construction using Solids, including detail drawings to fabricate the parts.

It is decided to submit an application with the IWT (“Innovatie door Wetenschap en Technologie” = government agency for Innovation through Science and Technology). The application is approved.

Following an international inspection, the roof tile is sold by SMARTROOF since 2011.

Because of the unique and complex nature of this project Darvan fabricates all the parts and moulds themselves using specific technologies.

See the following steps for the full explanation of the machining processes (such as 2.5D milling, wire erosion, sinker erosion and moulding technology).

The complex surfaces are shaped in the moulds using a high speed milling machine.

For wire cutting, an electrode in the form of a brass wire is used with a diameter of 0.25 mm. With this instrument contours are outlined that can be finished both cylindrically and conically. The precision level is very high (0.005 mm). All conducting materials can be used in this process including substances such as hardened materials and carbon.

With the use of sinker EDM a preformed electrode is printed onto the work-piece by means of spark erosion.

The result has a precision level of 0.01 mm and a surface roughness of up to 1 µm Ra.

A tunnel sprue is a conical channel that must be used in varying X, Y and Z directions inside injection moulds.

For this purpose Darvan makes use of the sinker erosion process: a CNC programme is created whereby the spark process follows a path that simultaneously changes in the three axis directions.

Punching moulds (follow-on tools) and plastic moulds
provide the parts.

Traditional vacuum forming carries a considerable amount of waste. With this machining process, the products are formed in pre-cut sheets keeping the loss of material to a minimum.

Moreover, this production process decreases the energy consumption by 90%. Both electrically and pneumatically there is a very large reduction in energy consumption.

This is an innovative technology.
With the use of 3D simulations and solids a new machine is designed.

The decision is made to submit an application with the IWT (“Innovatie door Wetenschap en Technologie” = government agency for Innovation through Science and Technology).
The application is approved.

The project becomes operational in the course of 2012.

For this case Darvan uses a number of specific technologies.
They include among others the following machining processes:
CNC milling, conic wire cutting and moulding technology.

See the following steps for more information on the processes.

The material is cut by chip removal on a computer-operated machine by means of a rotary tool (the milling cutter). With the use of CNC machines complex parts can be finished at a fast pace and with high precision.

For wire cutting, an electrode in the form of a brass wire is used with a diameter of 0.25 mm. Darvan is specialised in wire cutting conic shapes.

The vacuum forming mould constitutes
the core of the machine.

The engraving process includes the photographic application of an acid-resistant coating onto the metal plate. The coating is subsequently developed in a lye solution. Afterwards the metal plate is eroded using an acid substance. The surface areas that are not protected by an acid-resistant coating are eroded and removed up to the required depth.

This process is highly environmentally harmful and carries some risks. Darvan produces the text by applying the sinker EDM process by means of an electrode which eliminates the chemical substances.

Darvan takes all the initiatives and pays close attention to the design of the text roll. The text must be adapted in function of the sinker EDM process.

In this case Darvan uses a number of required and specific technologies such as micro-milling, unwind sinker erosion and CNC turning.

The text is put into a carbon electrode on a high speed milling machine by means of micro milling tools with
a diameter of 0.1 mm.

With the use of a micro mould sinker EDM machine the text roll is unrolled on a flat electrode. A polishing machining process makes sure that the text is neatly defined.

Turning is the chipping technique whereby the product rotates and produces the cutting movement. The movement in longitudinal and transverse direction is executed by the cutting tool. The process is computer-operated (CNC) meaning that complex forms are no problem at all.

The text roll is made by Darvan with the use of machining processes such as turning, milling and boring.

In order to produce a plastic strip with raised 3D forming, the plastic strip is heated and shaped using a complex machining process with a reverse shape.

The strip is subsequently fitted to the required size (width). This time-consuming process uses a considerable amount of energy and carries a lot of waste material. By extruding the strip to size and instantly creating all kinds of forms (both internal and external) in a rotary motion, the production process is highly simplified and is a lot more environmentally friendly.

Darvan takes all the initiatives and pays close attention to the design of the roller die and the nozzle of the extrusion die.

For the upsetting process Darvan uses a number of required and specific technologies such as conic wire cutting, sinker erosion, CNC turning and profile grinding.

See the following steps for the full explanation of the machining processes.

Material is removed by means of an unwinding wire with the use of controlled spark discharges.

Darvan specialises in producing conic forms.

With the sinker erosion process a preformed electrode is imprinted into the work-piece by means of spark discharges.

Turning is the chipping technique whereby the product rotates and produces the cutting movement. The movement in longitudinal and transverse direction is executed by the cutting tool. The process is computer-operated (CNC) meaning that complex forms are no problem at all.

Profile grinding is the grinding machining process whereby the grinding wheel takes the shape of the profile to be realized. With this process the smallest possible grinding radius in acute angles is 0.02 mm.

Both swing frame grinding and profile cylindrical grinding are applied. With swing frame grinding, the grinding wheel moves in a reciprocating motion to make line contact. Profile cylindrical grinding makes it possible to grind circular work-pieces with an accurate profile.