Our Approach to the Design Phase

During the initial phases of product development, the team at Gibbs works with the customer to resolve any technical or castability issues.  Initial parameters are developed for the casting conditions as well as manufacturing planning.

Product Development
Gibbs utilizes a three phase approach to product development. The unique knowledge blend of Casting Engineering, Die Engineering, and Metallurgical Engineering allows Gibbs to take advantage of the best die and alloy materials for the proper applications.

  1. Feasibility Review - Pre-quote review of product to determine castability issues
  2. Technical Review – Engineering review of product with customer to resolve technical issues
  3. Prototyping – four type of capabilities available
  • Rapid Prototyping – Gibbs completes for all new programs
  • Sandcasting prototyping – Utilizing outside approved resources
  • Rapid Die Cast Prototyping – To produce Die Cast Prototypes
  • Production Intent prototyping - To eliminate prototype costs

Process Development
Casting conditions and parameters are developed utilizing PQ2 calculations and NADCA standards. Flow, Solidification and Thermal Distortion software tools are used to simulate the casting process. These simulation results allow Gibbs to determine optimal tool configuration and process set-up conditions prior to all tool builds.

Process Design 
In-house capability for manufacturing cell design and integration utilizing tools such as Inventor and RoboGuide.

Die Design 
Gibbs utilizes Unigraphics for tool designs, part prints, and 3-D CAD models. We can also accept CAD data in C3P Ideas, Catia, DXF, STEP and Parasolid formats.