bf1systems are to undertake any level and complexity of composites design; from box design all the way through to Formula 1 steering wheels.
Utilising both CATIA V5 and NX for design, with HyperWorks for FEA, bf1systems is able to do anything from taking a customer’s concept and turning it into reality, or taking an existing design and confirming its suitability for production, then designing tooling, and producing all documentation required for production.
The bf1systems design department utilise both CATIA V5 and NX for composites design, along with Hyperworks for FEA. We can work with custom supplied CAD models, or can create CAD models from scratch, depending on the application.
As part of the design process, our designers will advise you on material choice, suitability of the component’s shape for manufacture, and also on the finish required for the part.
Every part of the design phase is managed according to our internal Quality Management System, which is adapted to ensure suitability of the part for the final application, be this anything from running on a Formula 1 race car, through to being fitted to a commercial airliner.
As part of the design phase, lay-up books are produced in conjunction with our manufacturing engineers for the composite laminators to use during the assembly phase. Assembly and inspection drawings are also produced for use by the laminators, trimmers and mechanical inspectors, throughout the assembly process.
In addition to designing pure composites parts, bf1systems also have a wealth of experience designing and building composites parts that require electronics integrated into them. Examples of projects that have relied on this close working relationship between the electronics and composites departments include 2013 and 2014 Formula 1 steering wheels, and centre consoles for a number of applications including WRC.
Tooling design and production is a critical stage in the design cycle of a composites part, as it ensures the quality of the end part if achieved.
Tooling can be designed and produced either from a customer’s design, or from our own CAD models.
Tooling for the manufacturing phase can be produced from a range of materials, including machined aluminium, tooling block or rapid prototype, depending on the application and time available for the project.
Once the tooling has been produced, it is subjected to a full dimensional inspection to verify its accuracy, and that the parts produced from it will match exactly the original CAD models.