Shapeable without limitation
Nanodur® has revolutionized
mineral casting technology
Fills the mould and compacts itself automatically
Using the cold-casting method, complex yet massive parts are made for the machinery industry in our Swiss manufacturing facility using the innovative high-performance material Nanodur®. Nanodur® is a cementbonded mineral cast, developed through years of research in the field of nanotechnology by our technology partner and binder manufacturer, Dyckerhoff. Unlike epoxy resin-bonded mineral cast, this material spreads and compacts itself, so that the mould does not have to be vibrated during filling. Nanodur flows and compacts itself automatically. Thanks to its excellent processability, inexpensive and easily obtainable wood or plastic mould is often sufficient. Only where mould has to meet the highest durability and precision standards is steel recommended.
High-performance material for engineering and nature
Optimized for highest packing density
Using nanotechnology, the cast stone is optimized to ensure highest packing density, which is visibly noticeable by looking at the smooth surface. It can be dyed completely or subsequently varnished.
Environmentally friendly processing
A research project funded by the German Federal Ministry of Education and Research has shown that Nanodur® has a far more favorable ecological footprint than epoxy resin-bonded mineral casts. No solvents are required during processing because water is fully sufficient to subsequently clean tools and equipment.
Climate protection and safe disposal of old machinery
The manufacturing of Nanodur® uses less energy and emits less CO2 than the manufacturing of epoxy resin-bonded mineral casts. Thanks to its purely mineral composition, crushed Nanodur® can be reused as fill material in road construction or as aggregate in recycled concrete.
Comparison of various materials
for machine beds
|designation||Nanodur® (mineral cast with cement)||Mineral cast with epoxy||Granite||Grey cast iron (cast iron with lamellar graphite)|
|Flexural tensile strength||N/mm2||18-20||15-35||10-30||150-400|
|Modulus of elasticity||kN/mm2||45-50||20-45||40-60||80-140|
|Coefficient of thermal expansion||µm/(m*K)||10-11||10-20||5-11||10-13|
|Specific thermal capacity||J/(kg*K)||750-1'000||750-1'000||750-1'000||460-540|
Using exact mould, we cast blanks with a surface accuracy in the tenth-millimeter range. By tempering the hardened material, excellent form stability is achieved. Progressive setting processes of the hydraulic binders and the associated shrinkage deformations are stopped by tempering. Evenness accuracy in the micrometer range is achieved by post-processing of the hardened blanks. Stone cutters accurately cut contact surfaces so that attachments such as steel rails can later be accurately mounted. Alternatively, cast steel components are directly machined to the specified final dimensions by metal processors.
The machine bed must effectively dampen disruptive vibrations from machine movement and interaction between tool and workpiece. The damping performance of Nanodur® is comparable to that of natural stone or epoxy resin-bonded mineral cast – that is up to ten times better than that of grey cast iron.
Conclusion: Highest precision with fast feed speed, noise reduction and extension of the tool life.
Comparison of vibration behaviour
The graph shows that Nanodur® induces less vibrations than grey cast iron and dampens vibrations much faster.
Due to its high specific thermal capacity and yet simultaneously low thermal conductivity, Nanodur® reacts significantly slower to thermal energy than grey cast iron. Inaccuracies caused by room temperature fluctuations are significantly reduced by the material-specific thermal inertia. In order to actively control thermal deformations from process heat as well as from external and internal heat sources, heating and cooling pipes can be moulded into the massive machine bed.
Thanks to the thermal inertia of Nanodur®, the transfer of fluctuating room temperatures to the machine is negligible.
in mould making
Engineering and design in harmony
Good news for machine
manufacturers Lend your brand a connotation of exclusivity by means of attractive, distinctive design. Turn your technical form into a consistently branded product and thus strengthen your market position. We can advise you on creative possibilities and implement the potential of the self-compacting flow compound with intelligent mould construction.
Cast stone with reproducible properties
The purely mineral casting compound hardens to cast stone with reproducible mechanical and physical properties at ambient temperature without any energy input. As in natural stone engineering, smaller individual parts can be glued to a larger part in the case of very complex shapes.
Elegantly embedded technology
In the cold casting compound, you can incorporate component parts (rails, anchor plates, threaded sleeves, transport anchors, hydraulic piping, grounding, cables, empty plastic pipes) into the machine bed in a compact and visually appealing manner. The frost-resistant mineral cast is not flammable and therefore resistant to flying sparks. As a result, steel components can subsequently be welded to anchor plates, which are moulded to the hardened machine bed.
Economical even for small- scale production and heavy machine beds
Thanks to the lower fix costs of mould making, the advantages of the mineral casting technology can already be economically exploited for small-scale production. The material cost for Nanodur® is lower than for epoxy resin-bonded mineral casts. This cost advantage is particularly evident in the unit price of large and heavy machine beds. Furthermore, in contrast to steel and oil, the material is unaffected by world market fluctuations. Steel mould
Bed rest for
Metal and wood processing machines
Pick & place applications
A strong foundation
Maximum production – minimal interfaces
What applies to humans is equally applicable to machines: a good bed is the basis for a successful day’s work. This is why we have specialized in the development and the production of ambitious, high-precision machine beds and tool frames. By working closely with qualified partner companies, Frei Engineering is able to offer you a complete service from dimensioning to blanks production, measurement, varnishing, subassembly through to precise post-processing with stone cutters and metal processors. In the end, this means for you: maximum production – minimal interfaces.
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