Case Study - EV Transportation

ARRK SUPPORTS NEW MOBILITY PROJECT
Through the product development activities of ourcustomers, ARRK finds itself at the heart of theevolution of society. We are increasingly collaborating
on “new mobility” projects. Given our experience
serving the automotive industry, ARRK is also able tosupport clients in the electric vehicle, non-motorized andother autonomous mobility sectors. One client ARRK

was able to help was Vega Chargers and their electriccharging station project.
VEGA CHARGERS, DESIGNER OF CHARGING SOLUTIONSFOR ELECTRIC VEHICLESVega Chargers sell charging stations for three-phase

PRODUCING SMALL VACUUM-CAST SERIES ON DEMAND

electric vehicles (cars, trucks, boats, helicopters). TheSince 2021, ARRK has supported the development andcompany is involved throughout the life of the product,

manufacture of Vega Chargers. Thanks to ARRK’s flexibility andfrom the product design, manufacture, marketing andthetheadditional parts, as and when required . ARRK initially delivered

installation/maintenanceofits

equipment

vacuum casting process , the customer can reordera batch of 10 wall boxes, then 20 in 2021, then a series of 50

throughout Europe.

units in 2022, followed by a further 100 units in 2023. In a few

FROM RAPID PROTOTYPING TO PRODUCTION

weeks, ARRK is able to cover the entire production cycle:

Vega Chargers first called upon ARRK to prototype its

manufacture of the master, the silicone mould, then theAloha

polyurethane parts, finishing and painting.

Gravitymodel,

awall-mounted

charging

station. ARRK provided a box machined in ABS material,
and the blue "ears" in rubber-like PU resin to simulate
the foam material of the final product.

LARGE VACUUM CASTINGS
ARRK’s production capabilities allow for the manufacture of asingle polyurethane part up to 2300 mm in length and a weightof up to 12 kg. The Vega Chargers wall box, measuring 760 x475 x 260 mm and weighing 6 kg, could be taken care ofwithout difficulty.
3d Printing | Prototyping | Vacuum Casting | Mock -ups | cnc | rapid tooling

PROTOTYPING & MANUFACTURING SOLUTIONSCase Study

ADVISING THE CLIENT THROUGHOUT THE PROJECT - OPTIMISING THE DESIGN OF THE CABINET TO ENSURE ITS WATERTIGHT
Vega Chargers wanted to optimise the design of the charging station to achieve a perfectly waterproof product that can be usedoutdoors. The client knew they could count on the support of ARRK’s experts to improve certain technical details. Afterreviewing the 3D files, ARRK made some suggestions regarding wall thicknesses and draft angles.
MACHINING ABS PLASTIC MASTERS
Due to its complex geometries, the master of the Vega Chargers box was manufactured through CNC machining , in ABS
material. Thanks to this selection, the customer was able to test the assembly and the various components before moving intoproduction.

THE ADVANTAGES OF ABS-TYPE POLYURETHANE RESIN
It was agreed that a low volume quantity of Vega Charger boxes would be produced using vacuum
casting and that the parts would be produced in an ABS-type PU resin. The client's specifications
required material properties compatible with outdoor use and in public places. It had to have thefollowing qualities:• Good impact resistance: to reinforce the internal metal structure of the box• Environmental temperature stability: from -20°C to +50°C• Resistance to moisture and fire: to preserve the high voltage electronic components inside the box• Dimensional stability of large format and thick-walled parts• Sufficient rigidity to securely fasten metal inserts• Easy to paint for aesthetic surface appearance
THE CHOICE OF AN EPOXY PAINT TO IMPROVE THE ROBUSTNESS OF BOXES
While we usually paint the vacuum-cast parts with polyurethane paint, in this instance, ourteam recommended an epoxy paint to reinforce the robustness to the external elements ofthe Vega Chargers box (bad weather, scratches, etc.).
Prior to the finalization of the parts, our Paint shop provided samples to the customer sothat they could test the quality rendering of this top-of-the-range paint.
THE COLLABORATION CONTINUES!
The low volume manufacturing run for Aloha Gravity bollards is now well establishedand up and running. Vega Chargers is expanding its offer with a self-supporting terminalmodel (Aloha Lander). In 2023, ARRK will continue to support the client and will supply
35 sets consisting of the top and bottom covers of this model. These parts have complex
geometries but as before our vacuum casting solution serves their requirements well.

For further information on ARRK’s range of services, please contact:
ARRK Europe Ltd
Unit 11, Olympus Park, Quedgeley, Gloucester. GL2 4NF, UK
Tel: +44 (0)1452 727 700 Email: projects@arrkeurope.com

uk.arrk.com
3d Printing | Prototyping | Vacuum Casting | Mock -ups | cnc | rapid tooling

PROTOTYPING & MANUFACTURING SOLUTIONSARRK Europe Limited, a limited company registered in England and Wales with registered number 3418673. Its registered office is Caldwell Road, Nuneaton, Warwickshire, CV11 4NG, United Kingdom