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BIRMINGHAM, UK – February 14, 2001 - The multi-shot moulding expertise of SMP Multi-Shot Ltd., together with Delcam’s Power Solution CADCAM software, played a major part in the development of the revolutionary new Bioform bra launched by Charnos. The company, based in Torquay, UK, has a long history in this specialist area of toolmaking. In 1996, its then parent company, Sifam, became the first moulder in the UK to install a three-shot injection moulding machine, allowing the combination of three elements in a single component. Although it is now an independent company, SMP has continued to develop its skills in multi-shot tooling, alongside its ability to produce high-precision single-shot moulds.

The development of the new bra began in 1998, when designers Seymour Powell undertook a radical redesign project for lingerie producers, Charnos, as part of a series for UK television station Channel 4. The objective was to create a new way of making a bra for the "fuller figure" that would provide superior support, comfort and fit, whilst overcoming the problems associated with conventional, under-wired construction.

Working closely with Charnos’s own designers, along with product engineers at another Delcam customer, product innovation consultants PDD, Seymour Powell created a revolutionary insert design. This acts as the foundation for the bra and also cushions and supports the breast in a way that provides both superior comfort and form.

To combine these two functions successfully, the insert is moulded of two materials with different characteristics. A high-modulus polypropylene is used to form a more rigid internal 'keel' which provides stiffening without discomfort, while a softer, body-forming elastomer is used for the cup supporting the breast. These materials were selected to provide the optimum performance, not only when worn but also when going through high temperature washing and drying cycles.

PDD recognised that twin-shot moulding would be the most efficient production method for the novel insert. It would also ensure that the two materials would create a single, inseparable component - one of the most common problems with the traditional design was the under-wires detaching in the washing machine. Extensive wear and washing trials were conducted to ensure that similar problems did not occur with the new insert.

PDD had worked with SMP on a range of other multi-shot mouldings and so was confident that moulds for the full range of sizes required could be produced in time for a launch before the Christmas demand reached its peak. However, once the full scale of the project was realised, SMP Managing Director, Anthony Fry, decided to sub-contract to Delcam’s Tooling Services Division the machining of the electrodes for sparking the final finish into the moulds.

"Accurate mould manufacture is essential for all multi-shot mouldings to ensure that the different elements of the component fit together perfectly", explained Mr. Fry. "It was even more important in this case as any inaccuracies in the moulded inserts would make the bra uncomfortable to wear. The combination of our technical expertise and our Delcam software meant that we were able to meet successfully the unique demands of the project, while the support of the Tooling Services Division allowed us to complete the moulds in time to meet the launch deadline."

http://www.delcam.co.uk 

 

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