ReVerie has a range of manufacturing facilties available to provide a composite product that has been optimised throughout the design, development and fabrication process. The sections below provide further insight into each stage of the design, development and manufacturing process.
Inventory included: Two Auto Claves and 8ftx15ft Surface Measuring Plate. Estimates Provided.
[Link to Services Offered]
Design Office | | The design office is able to provide no obligation quotes for a job quickly from an example part, engineering drawing or even a detailed sketch, although for more complex parts it is preferred that a solid CAD model is provided. For larger projects a project plan in the form of a Gantt chart is produced showing key milestones and outlining delivery schedules. ReVerie is equipped with a powerful set of 3D CAD and computer aided analysis tools to speed up the design and development of composite components whilst keeping costs to a minimum. The design and development department has many years experience in a range of industries with each member of the team bringing different skills and qualities. |  | | | |
Modeling & Surface Plates |  | ReVerie’s are able to produce scale or full size models of parts by hand or, for more complex parts, by Sub-contract CNC machining from IGES files. These models can be used as a pattern to produce composite mould tools or simply to prove out a concept. Alternatively, when dimensional tolerance is paramount, a tool can be machined directly from aluminium with correction made for differences in thermal expansion between the composite part and aluminium tool. Perfectly flat and level surface plates with a total area of 9m2 allow accurate measurement of any object up to the size of a large racing car for the purposes of gaining accurate dimensions for modelling or fitting purposes. | | | |
Prototyping | | Prototypes are developed in different ways depending on their purpose. To show styling features or other visual aspects of a part a prototype is normally created by hand using an epoxy or polyurethane modelling board material. To show satisfactory tooling methods at low cost, wet lay glass prototypes are often produced. ReVerie is able to produce a prototype to suit any purpose and any budget. ReVerie's experience in developing prototypes help us get it right first time. |  | | | |
Clean Room |  | In the cleanroom the manufacturing process begins. Sales orders that have been inputted to the computerised MRP system appear on the cleanroom work station in priority order. A job is selected by a kit cutting operative who assigns themself that job via a barcoding system and also records via MRP the details of the material used. Kits for each part are then cut from the raw materials using templates and the kit stored in a designated freezer. Generally speaking parts that are oven cured at 1 atmosphere pressure suffer a reduction in mechanical properties of about 15%, increased weight by up to 10% and don’t have the same quality of surface finish when compared with those that are autoclave cured. | | | |
Ovens | | ReVerie has a number of different ovens located in various areas of the factory. They are used for mould preparation, low cost vacuum only curing of parts and post curing of tools, patterns or components. Generally speaking parts that are oven cured at 1 atmosphere pressure suffer a reduction in mechanical properties of about 15%, increased weight by up to 10% and don’t have the same quality of surface finish when compared with those that are autoclave cured. |  | | | |
| |
Autoclaves | | An autoclave is effectively a pressurised oven allowing the curing of parts at up to 100PSI to ensure excellent consolidation of the finished part. ReVerie has three autoclaves of differing sizes, having the advantage of allowing the optimum size of clave to be chosen for a particular job, ensuring the best quality part and the lowest running costs. Large Clave : 100psi 230'c capability
1150mm diameter x 3750mm length x 800mm Z Small Clave: 100psi 300'c capability
480mm diameter x 750mm length x 380mm Z |  | | | |
Trim and Fitting Rooms |  | After cure the component is broken out of the mould and transferred to the Trim Shop. Here ReVerie’s experienced fettlers remove any excess material and prepare the part for final fitting through the addition of fitment holes etc. In the fitting shop inserts, fasteners and other items are assembled to the moulding to give the finished part. This will then be prepared as required, either highly polished or rubbed down matt ready for painting. ReVerie has an alliance with a nearby painting facility allowing parts to be provided with a high quality paint finish. | | | |
MRP | | Throughout the manufacturing process ReVerie’s MRP system allows the tracking of the part through every stage in the factory. Every job is assigned a unique number and barcode and before every process the operator will scan this barcode to inform the system that they have begun that stage. Once the process is finished the MRP system is again informed keeping a close watch on manufacturing times and providing feedback to the sales department to ensure that customers are quoted accurate prices for a job. An additional benefit of the MRP system is that it automatically records details of the material used for each part such as batch number, allowing full traceability at a later date. |  | | | |
Inspection |  | ReVerie has a full set of calibrated measuring equipment and a trained quality inspector ensuring that all parts leave the factory to the correct specification and required quality. Measurements are taken using a granite surface table (1525x1220mm surface area) as a datum. The majority of the measuring equipment used has a data output port allowing accurate recording of measurements on a data logging device and full inspection reports and certificates of conformance can be produced for each part. | | | |
)
)
)
)
)
)
)
)
