Die casting of special shaped bricks

Accessory roof tiles that cannot be produced by pressing are either luted by hand and “cemented“ by firing or cast by hand with very long setting times.

However, such a complicated production process can be avoided, and such long setting times extremely abbreviated, while expediently die casting as an integral whole all the parts that used to require subsequent assembly. Taking a mono-pitch tile as an example, this project investigates the potential suitability of the die casting process for products like roof tiles. The process is based on a pressure-die-casting composition consisting, apart from the electrolytes, exclusively of roof tile casting materials. The die casting tool was manufactured according to the rapid tooling process. Starting from a model, two blocks of polymethyl methacrylate are milled out to obtain the die halves. Such dies, including multi-part versions, can be plain cast, with casting times of five minutes for accessories being readily achievable, and multiple cavity dies can be used to further accelerate productivity. The application is also suitable for complex façade elements.

Thus, the die casting process is well suited for application to the manufacture of roof tiles and façade elements, and it is economically feasible for producing certain, particularly complicated shapes.

Dr. Jens Petzold, KI Keramik-Institut GmbH

Related articles:

10/2011

An innovation for integrated roof accoutrements: Röben‘s “solar docking tile”

Engineers at the Röben roof tile factory in Brüggen have come up with a special docking tile for in-roof solar energy systems on tile roofs, where the topmost row of roof tiles under a dormer, a...

more
8/2016 Wienerberger NL and Bongioanni Stampi

Weight optimization of a roofing tile based on FEM calculations

After the successful revamp of the Alegra 12 (formerly FD) flat tile and its accessories, the flagship model in the Wienerberger product range in Holland, it was the turn of OVH tile to undergo a...

more
05/2014 Bongioanni Stampi

Optimizing clay roofing tiles with finite element calculations

Faithful to company tradition, Bongioanni Stampi continues to support its customers with innovations and state-of-the-art technological developments.    The design of clay roofing tiles is no longer...

more
11/2013

Upgrading options for existing roof tile presses

Roof tile presses constitute the classic core component of any roof tile shaping line. In the course of their life cycles, they are likely to be modified a number of times. The average service life of...

more
2/2016

Nelskamp unveils new models and specials

The new “low-pitch roof tile F 8½“ series and some matching specials were presented by Dachziegelwerke Nelskamp at the Roof + Timber International Trade Fair. These brand-new F 8½ low-pitch roof...

more