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Unique tool design leads to new orders

A year and a half ago, Hjerno developed a unique new tool design in connection with a customer assignment.

And we are very pleased that this specific design has now led to further two major orders for the same type of tools from the same customer.

"After purchasing tools with a smaller number of cavities, the customer has now placed an order for two tools with each 32 cavities. It is the intention that this may perhaps be followed by orders for up to ten tools for this project, as the annual need for samples may rise to up to one billion," explains Aage Agergaard, Managing Director at Hjerno Tool Factory.

Cavities can be individually tested
The tool design, which, among other things, has been developed on the basis of Hjerno’s competencies in the field of collapsible cores, is unique, as the slide-bar and the draw of the tool practically go up and down instead of sideways as in conventional tool designs.

As something entirely exceptional, the individual cavities can be individually replaced while the tool is in operation. That is why Hjerno has built a one-cavity-tool that is placed in the factory and that makes it possible at any time to test the customer's individual cavities.

"Each cavity is basically a separate small injection moulding tool that operates independently of the cavity next to it. Thus, we can remove the cavity during the ongoing production and insert a reserve cavity instead, and - mind you - with a stop of only a few minutes. This is, as far as I know, never seen before in such a complex tool design as this," says Aage Agergaard.

Over 3,000 tool parts
The construction of the tool includes as many as 3,612 parts, of which 576 are forming parts made with a precision down to three micrometres.

The extremely high precision is simply necessary to keep the tolerance chain to a minimum when so many parts are included in the form.

"It is a good example of how it is worthwhile to go the extra mile in a project and invest both money and resources in new development. And also in this case it has proved to be able to pay for itself when we have finished the entire project," says Aage Agergaard.

"At the same time, the many holding tools and fixtures as well as the use of virtually all the technology available in the industry mean that we do now have a tool that is so special that we are probably close to being the only ones in the world, who can build it. And that is indeed a very funny thought."