The new orbital mould-holder system already improves the quality and productivity of soles, and by 2022 will be able to produce a complete shoe
The orbital mould-holder system patented by Ama Gusberti, which evolves the previous mould holders with forward/reverse movement, is a further departure from traditional fixed solutions and takes the quality of sole production to an even higher level. Orbital mould holders can move the mould both forwards/backwards and sideways. This system allows the robot, depending on the programming, to follow the entire contour of the sole, with the obvious advantage of extremely precise casting even in the undercuts, which is impossible to achieve with a fixed mould. This has a significant impact on the finished product in terms of superior quality, which is much appreciated by designer brands, always in search of production excellence. The system makes it possible to create, with very high precision, extremely complex soles that are impossible to obtain with traditional machines, while maintaining a high level of productivity, equal to, if not higher than, a classic carousel (300 pairs per hour). Each of the 48 stations works with two brushless electric cylinders, each equipped with its own internal encoder that makes the machine technologically advanced. It is so advanced that a further implementation is being developed to be combined with the orbital mould holder, already protected by the same patent, which will enable an entire shoe to be made with the same precision and quality.
Advantages: obtaining a high-quality shoe complete with sole and upper, without having to go through a subsequent assembly phase, but integrating the entire coupling process in a single casting operation, saving on costs and (a lot) on processing times. In addition to avoiding all the classic problems associated with gluing operations, casting on uppers will considerably improve the quality compared to traditional injections on uppers. In fact, the use of an open mould means that no air is trapped inside, and by casting on the edge, the expansion of the materials towards the inside can be developed, without any bubbles or imperfections being visible. Ama Gusberti expects to have this new system ready by early next year.