Design & Engineering

25 years experience in Composites and their manufacturing processes led Bercella to master this cutting-edge technology.

Advanced designing softwares and performing engineering tools are not enough to grant the best possible output. They have to be driven by a deep knowledge and by the capability to listen to the client and understand its needs, supporting it from the beginning until the end.

As a real one-stop-shop, Bercella provides design, manufacturing and testing all under the same roof.

Our engineering department uses the best 3D designing and FEM simulation softwares for:

Design
Industrialization and Tooling
Materials testing and qualification

Design & Engineering

Weight reduction, maximum stiffness.
Structural Optimization.
Environmental agents’ resistance.

How many times projects with a long supply chain faced issues due to different companies involved in designing and production?

How many times production costs increased during the project because of an initial underestimated budget compared to the necessary materials?

A wrong material, a mistake during the layup process or in the manufacturing flow can have a negative impact on the whole process, increasing the production costs, the total amount of needed time and, of course, the Total Cost of Ownership.

For this reason, we have collected and tested dozens of different materials, gathering experience and knowledge on their technical features and structural behaviour.

And then we use them to build several components in different shapes for multiple purposes; from tiny void-resistant pipes used in physics experiments, to the fifteen 4 meters in diameter Radomes and the 15.000 Structural Components for Railway Interiors.

We follow your project – or simply your idea – from the preliminary phases to its complete realisation, defining all the technical specs in order to provide the best solution for the need.

Thanks to our highly qualified Teams and to the use of the most sophisticated designing tools, we can help you with:

– Structural Design
– Statics and dynamics FEM analysis
– Vibrations and impact analysis
– Structural Composites optimization
– Topological multi-material optimization
– Environmental resistant design (MIL-810F, humidity, heil etc.)

Industrialization

Every project’s most critical phase is the industrialization one. It involves all the steps that bring the project to life, from the 3D software to reality. All the decisions taken during this phase will influence quality, costs and the future performances of the components.

Thanks to our curiosity, we have designed and realised several tools throughout the years, and this has been crucial to expand our specialisation in producing and industrializing prototypes too.

At Bercella you can rely on professional teams that will take care of your project while you will be concentrated on its future developments. We will industrialize your prototype with extreme precision, accuracy and repeatability.

Tooling and MGSE (Mechanical Ground Segment Equipment) design:

– Moulds for Autoclave
– Moulds for Compression Moulding
– Moulds for Carbon SMC
– Moulds for Thermoplastic Composites
– Bonding Jigs
– CNC Machining Jigs
– Assembly Jigs
– Painting Jigs
– Quality Control Fixtures
– Packaging for high-sensible hardware
– Project development and qualification
– Production flow optimization
– Test and final acceptance procedure definition

Materials testing and Qualification

Material testing is a basic process both in designing and production. It is necessary for our engineers to always rely on up-to-date data since we use the same processes and machines both in preliminary testing and in final production.

Thanks to this, our Quality Control department is able to rapidly analyse incoming materials assessments but also parameters’ process and intra-process needs.

Our Internal Material Testing Lab allows us to perform:

– ASTM, ISO, ECSS, SAE etc. mechanical tests characterization
– DSC and DMA tests
– Prepreg: density, void contents and fiber volume fraction measurements
– Subscale components tests
– ECSS insert qualification (pull-out, out of plane etc.)

Design & Engineering

Design & Engineering

Industrialization

Materials testing and Qualification

BERCELLA SRL

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