In this 2023 edition, Bruschi won his fifth NADCA Award thanks to a piece part of a complex opening system produced for FAAC S.p.A., a historic Italian multinational company specialized in automation for gates and barriers, automatic entrances and doors, car parks and access control.

This is a significant moment for the company, as it further solidifies its position of technological leadership in the world of zinc alloy die casting. This achievement coincides with the months during which Bruschi also emerged as a key player in the world of aluminum alloy die casting, thanks to the acquisition of SAPRE Srl, a historic Italian company specializing in aluminum alloys, all while celebrating its 75th anniversary.

Paolo Rastelli, CEO of Bruschi, made the following statement: “The acquisition of a new production plant for aluminum die castings and our company’s anniversary were significant milestones for us. They served to rejuvenate the energy we dedicate to our daily foundry operations, ensuring customer satisfaction. This fifth NADCA Award represents another such moment—a piece of news that ignites even greater enthusiasm and energy within the company. This recognition highly gratifies us, and I am confident it will motivate us to work with increased dedication and focus, striving to achieve further noteworthy results.”

This award joins the ranks of four other projects from Bruschi that have received this prestigious recognition:

• 1997 – NADCA Award: Bruschi earned this accolade through a historic collaboration with Olivetti, resulting in a printer featuring zinc components.
• 2001 – NADCA Award: A joint effort between Bruschi and Alcatel led to the creation of an Alcatel frame, garnering Bruschi the NADCA award in 2001.
• 2016 – NADCA Award: A partnership with ARCA produced the CM18 Reader component, designed by Bruschi through co-design, which allowed the requesting company to achieve up to 40% cost savings. This achievement earned Bruschi the NADCA Award in 2016.
• 2021 – NADCA Award: Bruschi secured the 2021 NADCA Award for designing and producing an aesthetic component for a well-known car manufacturer’s steering wheel, manufactured on behalf of ZF, an important Tier 1 company in the automotive sector.

For more information on Bruschi’s other award-winning projects, click here: Awards.

In the photo, Ermo Fusè, Strategic Technology Manager of Bruschi, receives the NADCA Award together with Luca La Ganga, Principal Mechanical Engineer of FAAC.

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In fact, as also suggested by ICE’s research (Agency for the promotion abroad and the internationalization of Italian companies), Italian exports have recorded some positive signs of exports to foreign markets, not only limited to the traditional sectors of the tip of the national economy.

To highlight these excellences and optimistically encourage the development of Italian exports, Il Sole 24 Ore and the international research company Statista have launched the announcement of the unprecedented “Export Champions 2022” award, a sort of ranking of Italian companies that, in the various industrial sectors, have distinguished themselves more for their international activity.

Thanks to the constant expansion of its market and effective worldwide commercial action, Bruschi was selected among the “Export Champions 2022“, a significant recognition for a very competitive sector, that of die casting.

Being among the champions of this edition is a source of great pride, the result of everyone’s work, done best with patient constancy every day.

So, congratulations! It is only with the commitment and collaboration of everyone that we can grow together!

You can find the official ranking published in Il Sole 24 Ore at this link: https://lab24.ilsole24ore.com/campioni-export-2022/.

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This important victory was achieved thanks to the creation of an aesthetic component for the steering wheel of a car of a well-known car manufacturer made by Bruschi on behalf of an important Tier 1 in the automotive sector.

The competition, organized by the North American Die Casting Association (NADCA), was created to promote the growing use of die casting in the various market sectors and rewards projects that have distinguished themselves over the last year in three categories of materials such as aluminum, zinc, and magnesium, then declined into weight classes.

The aesthetic component made by Bruschi won first prize during the Die Casting Congress and Exposition 2021 in Indianapolis on October 5, 2021 thanks to the motivation of being the first zinc alloy component ever assembled on a car steering wheel. Bruschi’s skills and the use of zinc alloy have made it possible to obtain advantages such as rigidity, stability, and robustness, as well as the possibility of a high-quality finishing, which other materials could never have obtained.

This success is the fourth NADCA prize awarded by Bruschi in the course of its history and projects the company towards new ambitious objectives to be achieved, always intending to be at the forefront of the die casting market and continuously receptive to new techniques and methodologies to apply to everyday operations to contribute to the improvement of the sector. Click here to discover all the awards won by the Bruschi.

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Also this year, the Association of Italian Metalworkers (Associazione Italiana di Metallurgia – AIM) launched its 2020 Aldo Daccò Prize. The award was first established in 1975 to stimulate the sector’s technicians to contribute to the progress of foundry and solidification techniques through essays and original studies. Due to the restrictions in force, the award ceremony was held online on January 18^th, 2020 on the occasion of the opening ceremony of the 38^th AIM national congress.

In the 2020 edition of the Aldo Daccò Prize, Marco was awarded ex-aequo with Engr. Lavinia Tonelli and presented the scientific paper Compensation of Shrinkage Deformation in Zinc Alloy Die-Cast Components.

We interviewed him to learn more about his paper and compliment him on the great result obtained.

Tell us something about the contest you participated in – what is it and why did you decide to compete?

AIM is a non-profit cultural body and was founded in January 1946 with the aim of spreading the science and technology of metallic and other engineering materials. In the wake of its mission, AIM has been organizing this competition for 45 years. I have always followed it for personal interest and I have been looking forward to participating in it for a long time. Having worked at Bruschi Spa for the last few years, I decided to combine my technical knowledge and the experience developed in the field to contribute to the development of the knowledge of foundry and solidification techniques.

What does your paper deal with?

The paper presented is entitled: Compensation of Shrinkage Deformations in Zinc Alloy Die-Cast Components. In particular, it focuses on a specific criticality of zinc alloy die casts, i.e. the occurrence of product deformations caused by the shrinkage of material in the post-molding phase. In the paper I highlighted the difficulties encountered and the possible methods of solving this problem.

Why did you decide to develop precisely this topic?

The problems dealt with in my paper emerged during the inspection of particular products at Bruschi Spa. These problems were first discovered by our Quality Engineer Andrea Salmistraro. During the component analysis phase (performed with a 3D scanner), he noticed that some important dimensions were altered by a defect due to alloy deformation. Thanks to the involvement and contribution of our Strategic Technology Manager Ermo Fusè we hypothesized and subsequently demonstrated that this defect was related to shrinkage caused by Zamak solidification, which varies depending on mass distribution in the component. With my paper I intended to demonstrate that our solution makes it possible to counteract shrinkage deformations of material.

How did you get to the solution?

The first step was to verify that the mold did not have any alterations that could lead to this problem. Once the suitability of molds and sliders was ascertained, we analyzed two practical cases in which the components presented the same problem – despite their clearly different geometric characteristics:

• Flat surface deformation: in this case we started by scanning the deformed piece. Thanks to a CAD software, we extrapolated a lattice and used it to digitally reconstruct the deformed surface and then symmetrize it to obtain a counter-deformed surface. Finally, we applied this surface to the corresponding molding insert surface in order to obtain a piece deformed in the opposite direction and – once cooled – a compliant die cast.
• Cylindrical surface deformation: we followed a procedure similar to the previous one, even if it was not possible to replicate and symmetrize the deformed surface due to geometry complexity. We then scanned the pieces to identify the deformed areas and – after delimiting them with our CAD software – we projected them directly onto the molding insert surface and lastly we counter-deformed them.

Your paper suggests that the deformations addressed are in the order of tenths or even hundreds of a millimeter – how did you guarantee the finish’s precision?

Thanks to his many years of experience and in-depth knowledge of the equipment, our CAM toolmaker and programmer Matteo Annovazzi was able to faithfully replicate the design. He created an accurate CAM program for the milling machine and he then used it to work the molds.

What do you think of this experience and of your victory?

I am very satisfied with the result. I am proud of the existence of entities committed to promoting progress, the exchange of ideas and the sharing of knowledge in this sector. I would also like to thank Bruschi Spa for allowing me to carry out the studies shown in this paper and the support received from the entire team. It is thanks to the collaboration of the various engineers and technicians of the Bruschi team that I was able to demonstrate that it is possible to counteract the deformations caused by material shrinkage by means of a voluntary and targeted counter-deformation of the molding insert surface that generate the surfaces affected by this problem. It is not my victory – it is a team victory.

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2020 Champions companies

Also this year Italy Post, in collaboration with the periodical newspaper of Corriere della Sera L’Economia, has published the result of its analysis on the best Italian SMEs. Among the 1000 companies selected in 2020 for the results of the previous years Bruschi has been enclosed in the 800 with a turnover between 20 and 150 millions of Euros worthy of mention among all Italian SMEs. This is a new recognition of the work that the company, with its over 200 employees between Italy and the United States, puts in place every day to achieve excellence.

As part of this initiative, Italy Post has selected and awarded, in addition to the 800 in the category in which Bruschi has been included, also 200 companies that have distinguished themselves for a turnover of between 120 and 150 million Euros and, as a corollary of the selection, this year, Italy Post finally highlighted also the so-called “Big Companies” with a turnover between 500 million and one billion Euros.

The companies selected as Champions 2020 have distinguished themselves, in the last six years, for the high levels of growth, profitability, capitalization and financial independence. The analyses of the Italy Post Study Center were conducted with strict corporate and Cagr, Ebitda, Rating and Pfn criteria. For a complete overview of the parameters, we recommend visiting the page dedicated to the Champions 2020 of the Italy Post website.

The picture that emerges from the panorama of the best Italian SMEs, the analysis stops however at the balance sheets at the end of 2018, is still very positive: these are companies that in the last six years have grown by 9.84%, passing from a total turnover of 44.7 billion in 2012 to 78.6 billion in 2018, with an average margin of the last three years of 16.42%, a ROE 2018 of 15.86%, an aggregate net worth of 46.4 billion and a ratio Average Pfn / Ebitda of the last three financial years equal to -0.25.

Champions companies are therefore companies with an enviable financial strength and which achieve above average profitability in all the main sectors, with an approach based on the will to invest and develop. These are companies that have managed to grow despite the economic crisis of 2008 and, until 2020, have proven to be sufficiently agile and capitalized to resist extremely difficult situations.

Bruschi, among the best Italian SMEs

Bruschi has been selected among the 800 Champions companies with a turnover between 20 and 120 million Euros, thus confirming the recognition of 2019. For more information on 2019, see the page “Bruschi selected for the “Champions 2019” project among the 600 best SMEs of Italy”.

In Bruschi we are proud to have been selected as Champions 2020. In this regard, we report the statement of Paolo Rastelli, CEO of Bruschi: “Being recognized among the best Italian SMEs is an important result for the company, the result of the daily work of the whole team. The award attests to the approach with which in Bruschi we face the challenges that the market presents us every day. An approach made up of courage and determination which, also during 2019, has allowed us to achieve important goals. Our model, which has so far proved successful, is based on three key principles: a strong orientation towards results, a propensity for change and a predisposition for collaboration.”

And it is precisely with these three key principles in mind that we look to the future, hoping to be among the best Italian SMEs also in 2021. We will keep you updated.

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Osservatorio PMI analyzes financial statements and data of over 60.000 Italian manufacturing and service companies and Bruschi is among the 722 awarded companies. This is why we are very proud of this achievement, also and especially because it is the second time our company reaches this goal.

Indeed, this award proves the commitment of the entire team to find advanced technological solutions that allow the company to be competitive on a global scale.

A further demonstration that the work of everyone can become a system able to lay the groundwork for the future: in order to reaffirm Bruschi presence on the market in the following years and to keep growing together.

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