IMG/IMGL Vacuum Form Tooling
25
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Transcript of IMG/IMGL Vacuum Form Tooling
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PLANTS
OVERVIEW
HEAD OFFICE MOLD MANUFACTURING 5-AXIS MACHINING NICKEL VAPOR DEPOSITION PLANT
ALL FACILITIES ARE LOCATED IN MIDLAND, ONTARIO, CANADA
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STATE-OF-THE-ART NICKEL CARBONYL PLANT COMMISSIONED IN 2000
4 PRODUCTION AND 1 R&D CHAMBER
24 X 7 OPERATION
400,000 LBS/YR NICKEL DEPOSITION CAPACITY
5.7’ X 15.3’ NICKEL SHELL SIZE CAPACITY
NICKEL VAPOR DEPOSITION FACILITY
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NICKEL VAPOR DEPOSITION
• A RE-USABLE DEPOSITION MANDREL IS PLACED IN THE DEPOSITION CHAMBER AND HEATED TO APPROXIMATELY 350°F.
• MANDREL MUST BE CLEANED AND PREPARED PRIOR TO EACH DEPOSITION.
RELEASED CO GASSES ARE RECYCLED
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THE NICKEL CARBONYL GAS FLOWS OVER A REUSABLE DEPOSITION MANDREL CREATING A UNIFORM THICKNESS NICKEL SHELL AT A
GROWTH RATE OF .010” PER HOUR REGARDLESS OF THE PART SIZE
SEALED DEPOSITION
CHAMBER
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ELECTROFORMING NICKEL VAPOR DEPOSITION
1. 0.25mm per 20 hour growth rate
2. Shell thickness is not uniform during growth
3. Inherent residual stresses during growth
4. Cavities made simultaneously from different
bath masters.
5. Problematic variation - cavity to cavity
6. Replace damaged shell in 10+ weeks
7. Delaminating risk as shells are created in
multiple grinding and growth steps
8. Sulfates contamination from electroplating
bath = difficult welding + de-lamination risk
9. Process waste is an environmental concern
1. 0.25mm per 1 hour deposition rate
2. Uniform thickness during growth
3. Negligible residual stress during growth
4. Cavities made sequentially from the same
re-usable deposition mandrel
5. Little variation from cavity to cavity
6. Replace damaged shell in 3 weeks
7. Full shell thickness is deposited in one
step with growth being very uniform.
8. 0.999 pure Ni – weldable and no de-
lamination risks
9. No environmental impact (closed system)
COMPETITIVE PROCESS COMPARISON
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TYPICAL APPLICATIONS FOR OUR NVD NICKEL SHELLS
HOT AIR SLUSH MOLDS
(TUBE BUNDLE OR FORCED AIR METHODS) PU SPRAY MOLDS
TEXTURED RIM OVERMOLDS HIGH POLISH PU OVERMOLDS
NEGATIVE VAC FORM IMG MOLDS
OIL HEATED SLUSH MOLDS
(OIL LINES ON SHELL BACKSIDE)
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WEBER PATTERN MAKERS CREATE THE LEATHER WRAPPED MASTER MODELS THAT WILL BE REPLICATED BY THE NVD NICKEL MOLDS
EXTENSIVE IN-HOUSE MANUFACTURING AND WRAPPING EXPERTISE FOR ANY INTERIOR PART SHAPE.
EXTENSIVE MASTER MODEL APPROVAL PROCESS EXPERIENCE WITH OEM’S AND TIER 1 SUPPLIERS.
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EPOXY CASTING, WRAP SEAM TEXTURE ENHANCING, AND CNC ENGRAVING OF FINAL EPOXY MASTER MODELS ARE DONE AT WEBER
WEBER PATTERN MAKERS CREATE THE FINAL EPOXY MASTER MODELS THAT WILL BE REPLICATED BY THE NVD NICKEL MOLDS
NVD NICKEL SHELL PROCESS FLOW INCORPORATING A LEATHER WRAP MASTER MODEL
Leather Wrapping of
Substrate
Cast Silicone Negative
from LWM
CNC Machine Leather Wrap
Model (LWM) Substrate
CNC Machine Mandrel Cast Silicone onto
Mandrel
Nickel Vapour
Deposition Process
Shell Stripping and
Mold Assembly Mold Inspection and
Approval
Repeat Steps for Multiple Molds/Shells
CA
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ata
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rder.
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el,
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Substrate CMM
Inspection / Approval
LWM CMM Inspection /
Commission
Enhance Epoxy
Model Seam Lines
Cast Epoxy Master
Model
Epoxy Model CMM
Commission / Inspection
Cast Silicone Negative
from Epoxy Master
Build Silicone
Support Mold
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WHAT ARE THE ADVANTAGES OF NICKEL VAPOR DEPOSITION OVER THE ELECTROFORMING PROCESS??
UNSURPASSED REPRODUCTION OF ANY GRAIN OR SURFACE TEXTURE WITH
ATOM BY ATOM DEPOSITION
NO CONDUCTIVE LAYER NECCESSARY
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ADVANTAGES OF NICKEL VAPOR DEPOSITION…
20x FASTER GROWTH WITH A MORE UNIFORM NICKEL SHELL THICKNESS
NVD NICKEL SHELL CROSS SECTION
ELECTROFORMED SHELL CROSS SECTION
NO RESIDUAL STRESS FROM NVD MEANS NO SHELL DISTORTION
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ADVANTAGES OF NICKEL VAPOR DEPOSITION…
THE NVD PROCESS HAS A NICKEL SHELL DEPOSITION RATE APPROXIMATELY 20 TIMES FASTER THEN ELECTROFORMING
THE NVD PROCESS TYPICALLY PROVIDES A 5-6 WEEK TIMING IMPROVEMENT TO THE FIRST MOLD COMPLETION
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ADVANTAGES OF NICKEL VAPOR DEPOSITION…
CONSECUTIVE NVD MOLDS CAN BE DELIVERED IN 2-3 WEEK INTERVALS AFTER
THE FIRST MOLD
EMERGENCY REPLACEMENT OR CAPACITY NVD MOLDS CAN BE DELIVERED IN 3-4 WEEKS FROM A KICK-OFF
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PRECISION LASER WELDING
TEXTURE REPAIR SPECIALISTS - ON-SITE OR AT CUSTOMER PLANT
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Current Mercedes M-Class
Doors – Front & Rear
Current Chrysler 300
Instrument Panels, LHD & RHD
Doors, Front and Rear & Console Panels
Current Ford Focus
Instrument Panels
Current BMW X3
Instrument Panels – LHD & RHD
Current Dodge Journey
Instrument Panels
RECENT AUTO INTERIOR PROGRAMS DONE WITH WEBER AND NVD NICKEL SHELL TOOLING
Current Nissan Altima
Instrument Panel Driver & Passenger Top Pads
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Current Dodge Charger
Instrument Panels
Doors, Front and Rear & Console Panels
BMW X5
Instrument Panels – LHD & RHD
Current Ford Edge
Instrument Panels
Current Peugeot 508
Instrument Panels
Current Ford Explorer
Instrument Panels
Doors – Front & Rear
RECENT AUTO INTERIOR PROGRAMS DONE WITH WEBER AND NVD NICKEL SHELL TOOLING
NEW INTERIOR WORK AT WEBER!
DAIMLER MLC DOORS – CAST SKIN
DODGE CHALLENGER IP – CAST SKIN
DODGE CHALLENGER DOORS – IMGL
DODGE CHARGER IP – CAST SKIN
FORD EXPLORER DOORS – CAST SKIN
FORD EXPLORER IP – SPRAY PU
FORD F150 DOORS - IMGL
FORD MUSTANG DOORS – IMGL
TOYOTA AVALON IP – CAST SKIN
DAIMLER TRUCK IP TOPPER – SPRAY PU
OPEL D2JO IP TOPPER – CAST SKIN
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IMG/L - Negative Vacuum Forming & Laminating
NVD Technology Benefits
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NICKEL VAPOR DEPOSITION FOR NEGATIVE VAC-FORMING
SIGNIFICANT TIMING ADVANTAGE:
5-6 WEEK IMPROVEMENT DUE TO
THE FAST NVD DEPOSITION RATE
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NICKEL VAPOR DEPOSITION POROUS NICKEL EXAMPLE
THE 0.18mm (.007”)VACUUM HOLES ARE CREATED DURING NICKEL SHELL DEPOSITION OR AFTER BY LASER DRILLING. FULL CONTROL OF VACUUM HOLE DENSITY FOR MAXIMUM VACUUM AND OPTIMUM GRAIN REPLICATION.
NICKEL VAPOR DEPOSITION FOR NEGATIVE VAC-FORMING
ELECTROFORM POROUS NICKEL EXAMPLE
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ELECTROFORMED POROUS NICKEL SHELL
VIEW OF SHELL BACKSIDE
VIEW OF SHELL SIDE & FRONT
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A VERY STRONG, SOLID NICKEL SHELL WITH ONLY THE VACUUM HOLES PASSING THROUGH THE SHELLS THICKNESS
NVD POROUS NICKEL SHELL
VIEW OF IMG SHELL SIDE & FRONT
VIEW OF SHELL BACKSIDE
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NVD POROUS NICKEL SHELLS
5-6 WEEK TIMING ADVANTAGE
CONTROLLED VACUUM HOLE PLACEMENT
SUPERIOR GRAIN REPLICATION QUALITY
INHERENTLY STRONGER NICKEL SHELL
COMPETITIVELY PRICED
MASTERED & MANUFACTURED COMPLETELY IN NORTH AMERICA
CAVITY IMG SHELL & VACUUM BOX ASSEMBLY VALIDATION BY VACUUM
BAGGING AND VACUUM PULL TESTING PRIOR TO CAVITY SHIPMENT FROM WEBER
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CONTACT INFORMATION
Robert Sheppard, P. Eng Vice President 705-527-2976 (Office) 705-527-2123 (Cell) [email protected]
Weber Head Office
16566 Hwy. 12
P.O. Box 399
Midland, Ontario
Canada, L4R-4L1
Alan Gobien Business Manager – Automotive Interiors 705-527-2950 (Office) 705-427-3600 (Cell) [email protected]
Weber Head Office
16566 Hwy. 12
P.O. Box 399
Midland, Ontario
Canada, L4R-4L1
Thomas Helle European Sales Agent +49 (0) 7021 978558 (Office) +49 (0) 7021 978557 (Cell) [email protected]
Greg Leidig U.S. Sales Agent 419-481-3645 (Cell) [email protected]
Stuckerinweg 12
D-73230 Kirchheim/Teck
Germany
2136 Woodmere Court
Toledo, Ohio
43615
