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The development of a direct-driven, miniature low-vibration compressor.

We were approached by Vert Rotors early 2015 with a project focused on a metal replacement program – aiming to reduce cost and weight while improving overall product performance. With a requirement of both tooling and moulding, Omega and Vert engineers began working together on the project, overcoming a number of challenges including heat and dimensional stability.

Utilising our Moldflow software during the design phase of the project, we were able to ascertain the feed gate position and filling sequence. By doing so, the product could be evenly filled and we could determine post mould shrinkage rates and and potential distortion – aiding the overall moulding process.

Using a combination of 5-axis CNC machining and EDM machinery, a fully automated tool using a pre-hardened tool steel was manufactured to produce a relatively low volume of prototype components. Due to the product having a working temperature of over 200⁰C it was essential that the material met the product’s challenging specification and working environment whilst maintaining dimensional stability.

Both teams worked together on identifying the right material using various grades of PPA (Polyphthalamide), PTFE (Polytetrafluoroethylene), PEEK (Polyetheretherketone) and Nylons – filled and unfilled. Numerous trials were carried out and the final material Carbon Filled Nylon was selected, due to its low coefficient of friction.

Today Vert Rotors continue to produce low-vibration compressors and build on an existing relationship with Omega Plastics.

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