Case Study

Reliable and Cost-Effective Hot Wire Cutter Solution with Customized PCB Design for a Leading Manufacturing Company:

A leading manufacturing company specialized in producing plastic-based fabrics, thin polystyrene sheets, and plastic films approached us with the challenge of improving their hot wire cutting process. The company was using an outdated and inefficient hot wire cutter that resulted in poor-quality cuts, frequent maintenance, and high operational costs. They required a more reliable and cost-effective solution to enhance their production process, including a customized board-level PCB design to ensure seamless integration with their existing equipment.

Objective:

Our objective was to design, develop, and implement a reliable and cost-effective hot wire cutter solution, complete with a customized board-level PCB design, that would improve the company's production process, reduce operational costs, and enhance product quality.

AFI Systems solution:

Our team of engineers and experts analyzed the client's requirements and developed the FireFly Thermocut, a state-of-the-art hot wire cutter controller. The FireFly Thermocut offers precise control over the cutting process, allowing the client to cut their materials with ease and accuracy. The controller is designed to work with various hot wire blades, making it a versatile solution for the company.

A critical aspect of the FireFly Thermocut's design was the development of a customized board-level PCB that ensured seamless integration with the client's existing equipment. Our engineers designed the PCB with considerations for power requirements, signal routing, and component placement, resulting in a compact and efficient design.

Key features of the FireFly Thermocut include:

• Advanced programming mode that allows users to set the desired cutting parameters, such as run power, standby power, preheat time, and preheat power.
• Run mode for efficient cutting operations, with seamless switching between standby and run power modes.
• Wiring guide for easy and safe installation of the hot wire cutter.
• Safety instructions to ensure the proper use of the device and prevent accidents.
• Compatibility with various hot wire blades, enabling the client to cut a wide range of materials.
• Customized board-level PCB design for seamless integration with the client's existing equipment and optimized performance.

Results:

The implementation of the FireFly Thermocut with its customized PCB design in the client's manufacturing process led to significant improvements in production efficiency and product quality. The following results were observed:

• Reduced operational costs: The FireFly Thermocut's energy-efficient design and reduced maintenance requirements led to a significant reduction in operational costs for the client.
• Improved product quality: The precise control offered by the FireFly Thermocut resulted in cleaner and more accurate cuts, enhancing the overall quality of the client's products.
• Increased production efficiency: The easy-to-use programming mode and run mode of the FireFly Thermocut allowed the client to optimize their cutting process, resulting in increased production efficiency.
• Many products can ship the same day they are purchased.
• Seamless integration: The customized board-level PCB design allowed the FireFly Thermocut to be easily integrated with the client's existing equipment, ensuring a smooth transition and minimal downtime during implementation

Conclusion:

The FireFly Thermocut, with its customized PCB design, proved to be a reliable and cost-effective solution for the client's hot wire cutting needs. The advanced features, precise control, and seamless integration offered by the controller led to significant improvements in production efficiency, product quality, and operational costs. The client was highly satisfied with the outcome and continues to use the FireFly Thermocut as an integral part of their manufacturing process.