CAD/CAM & FEM: Excellence through design verification

In manufacturing, it is not only the material or printing technology that determines the success of a component – it is above all the quality of the design and its testing. At Rejlek, we therefore consistently rely on CAD/CAM-supported processes and FEM simulations in order to identify potential weaknesses as early as the design phase, exploit optimisation potential and create the basis for economical, precise manufacturing. These technologies enable us to achieve maximum transparency and reliability – in every phase of product development.

In the following blog, we take a look at what exactly CAD/CAM and FEM are, what role they play in manufacturing, and how Rejlek uses them specifically to optimise costs, quality and process reliability.

CAD/CAM: The digital bridge from idea to production

Computer-aided design (CAD) enables complex geometries to be modelled efficiently and precisely. Computer-aided manufacturing (CAM) then converts these digital models into concrete instructions for machines.

At Rejlek, we rely on powerful CAD/CAM systems that enable us to transfer design changes directly into the manufacturing data – without manual transfer errors. This not only reduces throughput time, but also minimises the risk of quality defects.

FEM: Process reliability through injection moulding simulation

In injection moulding production, the manufacturing conditions have a decisive influence on the quality of a component. At Rejlek, we therefore rely specifically on simulation-based analyses to predict the behaviour during the injection moulding process as accurately as possible, right from the design phase. This is based on the specialised FEM software Autodesk Moldflow – a tool that was developed specifically for the analysis and optimisation of injection moulding processes.

Unlike general FEM programmes, which primarily simulate mechanical loads, Moldflow focuses on the physical processes involved in plastics processing. Unlike FEM simulations for component strength, the focus here is on the manufacturing process itself – for example, the flow behaviour of the material and the thermal influences in injection moulding.

This enables us to accurately assess the following aspects, among others:

• Filling behaviour and mould filling
• Shrinkage and component distortion
• Weld seams and air pockets
• Cooling time and cycle optimisation

These simulations enable us to identify potential sources of error in the process in advance and eliminate them before the first tool is built. The result: an optimally designed tool for reliable production within tight tolerances, short development cycles and maximum efficiency in series production.

By using Moldflow, we provide our customers with planning reliability, minimise expensive rework and simultaneously optimise costs, quality and process stability.

Precision through digital control

The success of a component depends largely on a seamless digital process chain. CAD, CAM and FEM are important links in this chain at Rejlek. From the initial design to simulation and final production, every step is data-based, traceable and validated.

One highlight of our quality management system is the integration of modern monitoring technologies such as Inline Weld Watching. This system monitors welding processes in real time, detects errors immediately and enables seamless documentation of the connection quality – another plus in terms of safety for our customers.

Quality as a principle – not just a promise

At Rejlek, quality is not something that comes at the end of the process, but is firmly anchored in every step. Our design checks are based on current standards, industry-specific requirements and comprehensive simulation. By integrating CAD/CAM and FEM at an early stage, we not only avoid costly rework, but also create products with maximum service life and functional reliability.

Our customers benefit from a holistic approach: optimised component performance, reduced manufacturing costs and short time-to-market – with a high degree of process reliability and documentation.

Conclusion: Technological strength for sustainable quality

Rejlek combines state-of-the-art digital tools with decades of manufacturing experience. The use of CAD/CAM and FEM not only ensures precision and efficiency, but also makes our processes future-proof. Through continuous investment in technology and expertise, we remain at the cutting edge – and deliver products that are both technically and economically impressive.

Would you like to learn more about our digital testing methods or customised solutions for your application? Talk to our experts – we will be happy to advise you personally and show you how we can bring your product idea to series production with precision and efficiency. Contact us now.