Technology integrator

From prototyping to mass production…

Saint Jean Industries has integrated a great deal of expertise since it was founded, making the transition from aluminum foundry GDC (Gravity Die Casting), LPPM (Low Pressure Permanent Mould) and COBAPRESS™ to turnkey manufacturer of machined, finished and assembled chassis parts for the automobile market.

In this section you will learn more about the technologies mainly used for suspensions.

Please do not hesitate to contact us regarding alternatives.

Prototyping

Saint Jean Industries develops its prototypes in-house with several options according to the number of parts required.

Sand casting: a secure dedicated workshop at the Saint Jean Industries Poitou site has the following technical capabilities:

  • Alloys: AS7G03-6, AS8U3G, AU5GT, AU5NKZR,
  • Max gross dimensions: 800 x 400 x 400 mm
  • Max gross weight: 50 kg
  • Prototyping, small to large production runs (< 1000 parts/year)
  • Machining and assembly

Billet machining: this process is used to obtain all types of parts made from any material in limited quantities.

COBAPRESS™

From the French for “COuler (Pouring) > BAsculer (Tilting) > PRESSer (Pressing)”

This patented technology is perfectly suited to weight-reduction, mechanical strength and freedom of design requirements for suspension parts.

Over 100 millions COBAPRESS™ parts manufactured until today

Description of the COBAPRESS™: this hybrid process consists of casting a preform and hitting it one time with a forging press.

Advantages over casting:

  • Improves material quality and properties : E155 ASTM < 1
  • Eliminates internal defects and optimizes mechanical properties
  • Reduces weight thanks to improved mechanical properties
  • Excellent fatigue resistance thanks to the skin effect of the COBAPRESS™ technology
  • Stable process enables frequency control in mass production
  • Perfect cohesion of metal inserts

Advantages over forging:

  • Alloy that is more economical and recyclable
  • Use of pins made possible, which reduces weight and machining costs
  • Reduces weight thanks to greater freedom of design
  • Allows production of more complex shapes
  • Stable process ensures improved quality control in mass production
  • Perfect cohesion of metal inserts

The characterization of the COBAPRESS™ process has been the subject of several scientific publications. The summary below provides a better understanding of the transformations produced during the manufacturing cycle and the subsequent results.

The COBAPRESS™ as a basis for innovation

The latest innovations in weight reduction

Two innovations at an advanced stage of maturity (Technology Readiness Level > 6) are currently offered:

  • The COBAPRESS™ Optimal (Optimized alloy) is a variant that offers mechanical properties improved by around 25%.
  • The Hollow COBAPRESS™ is a variant that optimizes weight and stiffness while retaining the advantages of COBAPRESS™

For more information about these two innovations, please request further documentation:

coabapress process

Aluminum casting

Aluminum casting is the historical core business of Saint Jean Industries. Whether gravity or low-pressure casting, these two technologies are available at the majority of the group’s sites. They enable the production of parts:

  • with complex shapes, hollow if necessary via the use of sand cores;
  • with average mechanical properties: Rm = 290 Mpa, Rp0,2 = 210 Mpa, A% = 6%.

All our tooling is designed and manufactured in-house, ensuring we are extremely responsive to your needs.

This is the first stage of the COBAPRESS™ process, which obtains a preform before the forging operation.

Gravity die casting: Our light, flexible and automated equipment delivers high production rates ranging from a few thousand to several million parts per item.

Low-pressure die casting: These facilities deliver high production rates with the use of multi-die molds through a central supply unit.

Bending of extruded profiles

In order to manufacture complex lightweight metal components and subassemblies with extruded profiles, Saint Jean Industries has specific capabilities for bending.

By investing in a new bending technology, we now own a modern 6-axis free-form bending machine. This allows us – through the contortion of the entire bending head to the feed axis – to bend asymmetrical profiles as well.

Further advantages of the CNC or 3D bending – compared to stretch bending – are among others:
• Intergradient radii can be bent transition-free
• Changes of complex bending geometries are directly possible via CNC control
• With one set of tools per profile various radii can be bent
• By continuously pushing the material, wall thickness of the outer curve is hardly reduced

Our capabilities:

  • Bending 2 dimensions,
  • Complex bending 3 dimensions.

Aluminum welding

Saint Jean Industries produces complex assembling of parts and sub-assemblies in light metal such as aluminum or magnesium.

Due to chemical and physical processes, the welding of aluminum components requires very high demands on the skills and equipment of the welding technician.

We have several computer-controlled 6-axis welding robots, which can weld even the most difficult compounds, such as the enabling of aluminum castings with extrusions – and in multi-shift operations.

A maximum degree of strength can only be achieved with optimal welding joints. Based on our many years of experience in welding light metal parts – e.g. in the automotive sector – we can ensure optimum quality.

Our capabilities:

  • Large part series on welding robot with rotary axis positioner
  • Manual welding for complex, small series and prototype parts
  • Secure friction stir welding from individual part to large volume production
  • MIG* manual welding
  • MIG and CMT** automated welding

*Metal Inert Gas / **Cold Metal Transfer

Machining and assembly

Saint Jean Industries produces complete machined and assembled modules.

Our capabilities

  • Study and production of machining and assembly fixtures in-house.
  • Cutting tools designed and produced in-house to optimize cycle times.
  • Dedicated or shared equipment as determined by the production volumes.
  • Fully automated, semi-automated or manual units as required.
  • Production of parts in small to large production runs.
  • Organization of production on a lean manufacturing basis.