NUMERO 1

The Masterpiece which carries the Tecnocad Foaming uniqueness

TECNOCAD PROGETTI S.p.A. is an Italian company active in the automotive and commercial vehicle sector since 1986, providing in-depth know-how in the engineering field, including the entire development process, from initial concept to small production batches. Based on our lengthy experience with the world’s leading auto makers, we can work on full vehicle designs with high-level know-how concerning the car body and chassis, closures, interior and exterior trims, the instrument panel, magnesium and composite components. Close cooperation between different specialist teams working on CAD Development, CAE Analysis and the prototyping workshop enables us to reduce development time and improve project quality. Our vocation for innovation, together with our technical background, has led us to develop a large number of ideas which we have first patented and then turned into finished products.

PURPOSE AND DISTINCTIVENESS After having developed the patent (finalized in 2011) and the first experiences in the production of components (2012), the application of Tecnocad Foaming originates in the first prototype demonstrator of our technology: NUMERO 1. Within its shapes, conceived to exalt the potential of in-mould leather upholstery, several peculiarities have been integrated which can be realized solely with the application of the patented technology. These shapes assume a degree of absolute difficulty if associated to the noble softness of the foamed component. This degree of softness would not allow the exact realization of the conceived shapes during the traditional method of manual upholstery. The component is made out of a single piece of leather skin, stitched to form before moulding. The use of multiple pieces of leather stitched together increases the degree of personalization in terms of materials, colours and shapes. The use of a noble material like genuine leather and the variety of personalization that can be obtained, makes the foamed component an exclusive and customized product, even being realized with standard production equipment.

The shapes are realized in the mould without other manual operations, that would not allow the realization of such radius on soft carrier.

01 Minimum radius on soft carrier

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By the use of sliders and mobile inserts it is possible to realize undercut areas, to be used as storages boxes, as an integrated function of the foamed component.

02 Storage space

Special light equipment allows to manage articulated and particular long stitching. The shown component contains 12 linear meters of stitching.

03 Control of stitchings

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It’s possible to realize concave depressions, even of reduced size, whereas the profile is true copy of the mould shape.

04 Concave Depressions

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In the same manner, convex surfaces can be achieved, without adding other materials below the leather.

05 Convex surfaces

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Introducing special stamps into the mould will lead to the marking of leather surfaces with logo or writings, guaranteeing the profile and the position.

06 Realization of logo

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07 Personalization of pattern

Through the use of sliders or inserts, well defined areas with special styling patterns can be created, depending on the required trim or the customer’s request.

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More Personalization: PATTERN

So a huge variety of pattern can be realized, giving live to new ideas and extending the customer’s styling freedom. It is also possible to make individual designs.

More Personalization: LOGO

Nearly any kind of writing or logo can be added, both in relief or impressed. Alternatively, writings can be embroidered.

More Personalization: COLOURS

Thanks to the pre-stitching of the leather skin, it is possible to combine an infinity of different colours and leather raw materials.

More Personalization: GLOVE BOX BAG

Even additional storage space in form of glove compartments can be integrated into the skin.

Manual loading of plastic skin into the mould

Loading of the Leather into the mould This operation is done by using a specific tool patented by Tecnocad

Foam injection and polymerization

Foam injection and polymerization

Extraction of the foamed component

Extraction of the foamed component

Trimming Glue spraying

Handmade Leather upholstering

FINISHED PRODUCT

FINISHED PRODUCT

Trimming

Difference lays in the process comparisation Traditional upholstery and Tecnocad Foaming

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BEGINNING