Based near Torino (Turin), CMP Bresso produces moulds for a variety of industrial sectors, including automotive, medical, sport flooring and electronics; at the turn of this century, it became one of the first companies in the Piedmont area of Italy to produce synthetic corks for bottles of wine.

Company owner Walter Bresso says that multi-cavity moulds were produced for the ‘corks’, whereas the trend at that time was to use single-screw moulds.

A challenge in another industry sector came with making moulds for plastic tiles used in sports facilities and capable of being installed on any foundation.

He says VISI software (www.visicadcam.com) played a vital role in creating a product that is now widely used in international markets.

“The customer brought us a plastic tile made by an American company and asked us to produce something similar.

“We designed a completely new tile, called Gimmy.

“It is a modular frost- and impact-resistant tile that’s non-toxic, anti-bacterial and made of completely recyclable techno-polymer plates.”

Mr Bresso said that the job was ‘child’s play’ with VISI.

In fact, he describes the software as “a good mate that’s always near us and is helping us constantly in everyday technological challenges.

“Simplicity and efficiency are two common features that can be found in all VISI solutions.”

“CMP Bresso has an internal mould design unit that is led by Mr Bresso’s sister, Daniela.

“The company operates a number of 3-D CAD stations using VISI Modelling — plus a CAM station working with VISI Machining 2D and 3D to create tool-paths.

Ms Bresso said: “We have been using VISI for over 20 years.

“Each project usually starts when we receive a 3-D file such as IGES, Step or Parasolid.

“We then create rapid prototypes in Acrylonitrile Butadiene Styrene — a common thermoplastic polymer — using a 3-D printer.”

Mould-making

Once the customer is happy with the prototype, the mould-making process begins.

To achieve this, CMP Bresso uses VISI Modelling, a solids and surface modeller that combines the Parasolid market standard for solids with Vero Surface technology, analysis tools and 2-D drawing.

Ms Bresso says: “It gives us complete flexibility in the construction, modification and correction of complex 3-D models.”

She says VISI Machining 2D gives her team a practical and intuitive solution for programming, while controlling the positioning of the fourth and fifth axes where required.

“The Feature Recognition option automatically creates intelligent and reliable tool-paths directly on the solid geometry, while the Operations Manager has a simple tree structure that shows us the various processing steps — along with full tool data.

“The operator can readily define machining parameters, cutting conditions and tool-holders, while the availability of multiple origins allows imported geometries to be quickly oriented around any reference — even for multi-axis machining.

“Moreover, VISI Machining 3D creates ‘advanced and intelligent’ 3-D tool-paths for machining even our most complex models, while its dedicated high-speed machining and smoothing functionality ‘softens’ the tool-path, allowing us to generate highly efficient ISO paths.

“It also gives quick calculation times, while the algorithms for optimising the NC code considerably reduce machining times.”

Company history

Established in 1968 as a mechanical workshop producing precision equipment, CMP Bresso diversified seven years later into making plastic injection moulds for the Olivetti group, which it still supplies today.

Mr Bresso says his company is not typical of traditional mould makers, as it can — and is willing to — solve significantly complex projects.

He says this is particularly true of the company’s ability to create moulds for thermoplastic products that were originally made of metal.

“A metal component can’t be reproduced exactly as it is in plastic, so we redesign it and then use VISI to create the mould to ensure that the part does exactly what it’s supposed to.”

Another solution to a complex issue involved ‘co-moulding’ a metal element of a car window component for Ford.

“Normally, that type of component is made of metal and coated with a primer — an interface agent that binds with the gasket rubber.

“The issue was that painting, along with the dangers of chipping and peeling, meant that the product was not reliable, so Ford asked us to come up with a solution.

“We co-moulded the product by covering the metal with a material that is compatible with the rubber gasket, so when the part is inserted into the mould the rubber sticks and becomes a single piece.

“Thanks to our experience, we managed to create a skin just 0.3mm thick that wraps the entire piece. Torsion tests showed that the device exceeds the limits imposed by Ford — eight-fold.”

VISI is also used to program CMP Bresso’s milling machines and machining centres, which produce about 30 moulds a year.

These are used on eight Arburg, BM and Ripress injection moulding machines.