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Making Complex Mold with 5-Axis Machining Achieving Great Accuracy & Productivity

Making Complex Mold with 5-Axis Machining Achieving Great Accuracy & Productivity

Customer challenge

ECCO is a global leader in innovative comfort footwear for men, ladies and kids with the slogan “Shoes you'll wear everywhere, because they feel so good”. Starting from 2019, they wanted to setup a new MoldShop department in Indonesia for making Outsole with the system Direct Injection Process (DIP) for their innovative comfort footwear with 5 AXIS machining facilities with the new team. The Direct Injection Process needed many mold tools because of using multi-section injection technology. Additionally, mass-production of highly complex shoe designs with many undercut profiles needs 5 AXIS machining technology, so the challenges that Ecco wanted to overcome are productivity, complexity, accuracy, precision and customization of software tools for automation.

Project goals

The following priority project goals were identified for the customer: 1) CAD design and manufacturing using 3 axis to 5 axis. 2) Ease of use to design complex shapes. 3) A macro to customize software tools for automation. 4) Dedicated post-processor for 5 AXIS and machine simulation. 5) Training and implementation with the customer’s projects running in their 5 AXIS machines.

Solution

With a reference from ECCO Thailand on the use of Autodesk tools for achieving the company goals, and to be able to understand the real benefits by the ECCO Indonesia team while attending the technical summit meeting at Thailand, the Senior Plant Manager of ECCO Indonesia contacted Hankook Delcam Indonesia for implementation of Autodesk advanced manufacturing solutions for die and mold with PowerShape and PowerMill 5 AXIS, especially for the shoe's outsole molding. Hankook Delcam Indonesia has quite good experience for the footwear company including some expertise in Macro/API development, training and implementation. Technical support and consulting continues from Hankook Delcam Indonesia, and the company is experiencing the strength of Autodesk PowerShape and Powermill 5 AXIS in many ways. In addition, the team is utilizing Macro/API programs for supporting PowerShape and PowerMill for the outsole mold for shoes with 5 AXIS machining.

Business outcome

The customer actually setup the mold shop from an initial two machines, CAD/CAM solutions and limited manpower. The first step was to get the training from the HDID team for PowerShape and PowerMill 5 AXIS solutions, then continue to implement the learnings on projects at ECCO Indonesia machining with 5 AXIS machines and making direct injection molds of shoes during the first 3 months. After that, HDID evaluated and reviewed the process and made action plans for making more effective, efficient and productive molds. With training, implementation , and Macro/APIs by Hankook Delcam Indonesia, the customer became faster, more productive and efficient for making the outsole injection molding with their 2 (two) 5 AXIS machines with high precision and accuracy. HDID supported ECCO Indonesia to manufacture high-quality, comfortable, state-of-the-art footwear and achieve what according to the ECCO’S vision is “TO BE THE LEADING PREMIUM BRAND FOR SHOES AND LEATHER GOODS”.

Conclusion

"We are very pleased with the partnership with Hankook Delcam Indonesia and Autodesk. ECCO Indonesia continues to always improve and be more productive in the manufacturing of outsole shoe molds with dedicated technical support from Hankook Delcam Indonesia for now and in the future." - ECCO INDONESIA

Project summary

    Duration & delivery

  • 30
  • 2020-03-29

    Autodesk solutions

  • PowerMill
  • PowerShape

    Services provided

  • Technical Support

    Customer industry

  • Design & Manufacturing
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