RESEARCH & DEVELOPMENT

RESEARCH & DEVELOPMENT

The engineering department, via Verbom Research and Development (VRD) develops new growth opportunities.

Product development for our clients involved with sheet metal and requiring industrial design, engineering, design, industrialization and mass production or prototype activities.

Applied research in the field of thermoforming of 5000, 6000 and 7000 series aluminum, as well as superplastic alloys such as titanium, magnesium and stainless steel

Methods of assembly of sheet metal components: structural adhesive assembly and various types of welding

Service for designing sheet metal parts outsourced at our clients workplace or from our offices, combined with finite element analysis of the forming process to ensure our design feasibility.

Experimenting and developing technologies related to the forming and the assembling of sheet metal.

In 2011, Verbom was the recipient of the Grand Prix Rio Tinto Alcan de l’Innovation for aluminium super plastic forming technology and for its contribution to the manufacturing industry.

Following this initial breakthrough in aluminum SPF, VERBOM is now capable of manufacturing large-scale and extremely complex parts using this process. The next step is to expand our expertise to other super plastic alloys, such as titanium, magnesium and stainless steel. The production of Boron steel through hot stamping was also studied for a project for structural parts for an ATV chassis. The high yield strength (1200 MPA) allowed for a significant gain in weight savings.

Structural adhesive assembly, whether with the family of epoxies or methacrylates, can significantly reduce the weight of components by using a thinner sheet metal. The adhesive, unlike welding, distributes stress without affecting mechanical properties.

  • $1M of annual investment in research and development

 

Our collaborators

PARTS DESIGN

As the specialists of your vehicles, you make sure they are made with only the best materials and techniques the industry has to offer. When it comes to your sheet metal needs, we are the experts you can rely on. With our extensive experience in the field of transportation, you can profit from the knowledge of our designers to fully exploit the potential of sheet metal. Through their mastery of sheet metal forming, they will be able to offer innovative designs while providing increased quality. The most functional solution at the best possible price.

Our team members can work on design in your offices, your engineering department, or from our offices under your supervision. The concepts that you will be offered will have the advantage of having been proven virtually in a numerical simulation process, to ensure feasibility and robustness.

Our team can deliver turnkey projects by taking care of industrial design and prototype manufacturing activities, physical or virtual laboratory tests based on your loading conditions, detail drawings with tolerance analysis, the industrialization process (tool and die, specialized equipment), and small or large volume production. This proven approach allows our customers to maximize their investment in product development.

  • 35% saving on your capitalized and part costs

RESEARCH AND DEVELOPMENT PROJECTS

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STRUCTURAL ADHESIVES ASSEMBLY AND “SANDWICH” WALL PANEL

To reduce vehicle weight and thereby cut energy consumption, Verbom used the thinnest materials possible while preserving mechanical property integrity. Structural adhesive assembly allows for the use of very thin sheet metal, and unlike welding, it does not alter the characteristics of the alloy. It also allows for the dispersion of the stress over a larger area.

We combined this technology with a honeycomb matrix made of polypropylene that was “sandwiched” between two aluminum sheets. The result was a lightweight and inexpensive rigid wall structure. Verbom then developed a method for numerically modeling this type of assembly to predict resistance under different loading scenarios.

  • At correlation tests, a load of 3000 lb (the weight of a small car) was supported with a sandwich wall of 4 ft. x 12 in. x 2 in.

 

  • 01 / 03
  • 02 / 03
  • 03 / 03

ATV STRUCTURAL PART DEVELOPMENT

Our extensive knowledge of sheet metal forming allowed us to propose a new welded alternative to a manufactured part that was relatively expensive. The finite element analysis, performed by Verbom, on the ATV chassis loads allowed us to achieve the equivalent mechanical strength, while significantly reducing production costs and product weight.

Verbom designed and built the new sheet metal tooling, produced the stampings and assembled the in-process parts with robotic welding.

  • 50% weight reduction
  • 01 / 06
  • 02 / 06
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  • 05 / 06
  • 06 / 06

TRAIN SEAT ENGINEERING

Verbom was mandated to design train seats in stainless steel and fiberglass with a tubular steel structure. For this major project, several standards and specifications had to be respected: those of the Toronto Transit Commission (TTC), the Chicago Transit Authority (CTA), the American Public Transportation Association (APTA), and the Railway Passenger Car Inspection & Safety Rule.

The project also included tolerance studies to ensure a robust/repeatable assembly during production. In addition to performing the finite element analysis, we had to perform over 30 different cycling tests in the laboratory to validate the mechanical strength and life of the components. All technical reports demonstrating specification compliance were written by Verbom, with the goal of having several types of seats for this rail project approved by the client.

  • 30 types of laboratory tests
  • 01 / 03
  • 02 / 03
  • 03 / 03

OLYMPIC TORCH

In collaboration with Bombardier Aerospace (official sponsor of the Games), Verbom developed and produced the Olympic Torch for the 2010 Winter Games. Verbom contributed to the redesign of the torch to allow for production.

  • 17000 torches manufactured.