From an idea to series production

Development competences

Inspiration – SAXONIA steers your product idea onto the road to success – book your test drive now!

Products are subject to complex requirements that can often only be met thanks to an elaborate product design.

When choosing a process, SAXONIA starts with inexpensive mass production processes such as stamping, fine-blanking, stamping/bending and develops these processes to the point of what is technologically possible.

Only when the requirements on the components can no longer be met with mass production processes will we turn to our process development.

Computer-supported simulation software and automobile core tools help with preliminary designs and optimization of our processes.

Together with you, SAXONIA develops products that are optimized and can be produced efficiently while meeting the requirement profile.

Our knowledge can best help you succeed if we are involved early on in the product development process.

If you do not yet know how, exactly, your product is supposed to look, we will take over the remaining development steps.

You provide:

  • Specifications
  • Assembly space and "collision data"

We deliver:

  • Development documentation
  • Calculation results
  • 3D dataset
  • Drawings and other specifications
  • analytic validation on the basis of static FEM calculations and other simulations.
  • the feasibility study on the basis of drawings.

The concluding validation is completed following joint coordination. Catia V5, Siemens NX and Solid Edge are available as development systems.

Prototypes (A samples) are often needed for the installation analysis or initial functional tests long before the scheduled series production.

Using different processes, such as water jet or laser cutting, milling or grinding, SAXONIA can build prototypes quickly.

Subsequent steps, such as barrel finishing, heat treatment or coating, assembly and joining operations are already taken through processes that are close to those used in series production.

By using our QUICKTOOL system, SAXONIA is able to build a sample close to series production (B sample) within weeks.

The insights and process data gained are taken into consideration during future series production.

Filling simulations help optimize the injection molding process during the product development stage.

Pressure and temperature distribution, the position of air pockets and joint lines are the result of a filling simulation.

As part of the product or process development, SAXONIA uses the insight gained from such simulations.

We use high-performance FEM calculation software during the product optimization of stampings and fine-blanking parts.

Forming processes, such as bending and embossing, fine-blanking and standard stamping processes, are calculated, analyzed and, if necessary, optimized using this numeric simulation.

By using these analyses early on in the process, development times as well as the costs for testing and optimizing tools are reduced significantly.

Industry applications