Thinking in MuCell January 2012
Plainfield Precision - MuCell User of MuCell since 2000 Multiple MuCell Machines in high volume production since 2002 Currently have Seven (7 ) MuCell machines 125 to 500 tons Three are rotary / Insert molding machines Perform mold trial services / sampling
50+ Years of Experience Company Overview Capabilities: Injection Molding: (18 to 500 Tons) ,complex insert, two-shot, precision, mu-cell and reel to reel molding Metal Stamping: (30 to 200 Tons), multi-slide components, pad printing, coil winding, contract riveting and welding Assembly: Automated and Manual 5 manufacturing plants worldwide: United States (3), Mexico, Dominican Republic Industries: Medical, Automotive, Consumer, Aerospace, Military, Electronics, Commercial
Core Capabilities Metals (stamping, multi-slide) Plastics (Injection molding) Value Add Insert molding & automated insert molding Assembly & testing
Locations Sturgeon Bay, Wisconsin, USA Precision Stamping, Multi-Slide, Pin Bandoliering and automated assembly Insert molding Plymouth, Massachusetts, USA Engineering Development Center. Insert, MuCell and Precision Molding, Pad Printing, Automated Assembly Santo Domingo, Dominican Republic Precision Molding, Pad printing, Lens molding and assembly San Luis Potosi, Mexico Insert, Two-Shot and Precision Molding, Pad Printing and Assembly Plainfield, Illinois, USA Precision Molding, Thermoset Molding, Pad Printing and Assembly 5
Plainfield Precision - Locations Sturgeon Bay, WI Plymouth, MA Plainfield, IL Irvine, CA Santo Domingo, DR San Luis Potosi, MX
MuCell for Unique Solutions Our experiences go beyond “Weight Reduction”
Air Meter 2003 GM GMT 610 Platform 2002 SPE Automotive Innovation Award Winner Category: Process / Enabling Technologies MuCell Benefits Superior thermal fatigue properties vs solid Eliminated sink marks Significantly reduced warpage Improved Dimensional Stability 12% weight reduction Air Flow Meter Flow Tube and Carrier Material: Celanex 6500 PBT Glass-fiber/mineral-filled
Hot runner valve gates used Reduced warpage Improved assembly fit Air Flow Tubes First mold initially built for solid material, ran in MuCell without changes 5 different tubes, 8 molds Hot runner valve gates used Reduced warpage Improved assembly fit 12 % weight reduction 30% cycle time savings Reduced time to market (debug time)
Tube – Warpage
Tolerances – Large Inner Diameter
Air Meter Sink Area Flat
Generation1.3 Air Meter 2-3% weight reduction Eliminated sink, distortion and warpage in thick wall Reduced distortion of connector Reduced flash MuCell enabled us to fill “tab” area of part
Air Meter MuCell Solid
Generation 1.5 Air Meter Two-shot, insert molded, Pre-mold/Overmold process Insert molded pre-mold is molded using MuCell Results: 10% weight reduction Minimal flash at shutoff areas compared with standard molding Reduced chance of insert movement during molding 20 % Cycle time reduction* *excluding insert load time
Minimal Flash 30X magnification – minimal flash (leak) at critical “shutoff” areas
Insert Molding Advantages Small traces, tight spacing Very Sensitive to molding pressures Traditional high pressure molding causes electrical shorts
Junction Connector Block Process Flow Stamping, Assembly of stamping to “pre-molded component Overmolding MuCell utilized to resolve “leakage “issues Part was not designed for MuCell Polymer is Nylon 6/6, 40% glass filled Component must pass USCAR Class IV requirements Other benefits: Cycle time Part weight
Junction Connector Block 12.5% weight reduction Cycle time reduction 30 to 25 Hold time from 6 to 0.5 Inj time from 1.2 to 0.4 Mold open/close 0.5 less (lower hydraulic pressure) Material: Nylon 6/6 Problem: water leakage past substrate interface Solution: MuCell allowed faster fill which created tight seal around substrates Saved $215/day in material Able to produce 2100 more pieces per day
Overall MuCell Experiences Cycle time savings – in most cases Reduced tonnage required – in most cases More uniform shrinkage (less distortion, sink, warp) – in all cases Reduce leakage – improved seal around substrates Material reduction – in most cases Benefits from Low cavity pressure – where applicable Minimized distortion around insert molded substrates Additional variable in process Training Maintenance – replacement parts 20
Future MuCell Growth at Plainfield Precision Why? We have a developed competency Existing equipment Years of Knowledge of process and tooling Differentiation to our customers MuCell solves problems and lowers part cost Investment cost for MuCell continues to drop – ROI Complementary technology to insert molding How? Expand Equipment range and type – more machines Quote as cost saving option Weight savings, cycle time, etc. Solve technical problems (with indirect cost savings) Always ask “Why not?”
Key Business Development Contacts Plainfield Precision Key Business Development Contacts Key Contacts Position E-Mail Seth Christian VP Sales & Marketing schristian@plainfieldprecision.com Jonathan Soucy President, Advanced Technology Group jsoucy@plainfieldprecision.com Ian Macleod Vice President, Technology imacleod@plainfieldprecision.com Rob Kretzmer Sales Development – West Coast rkretzmer@plainfieldprecision.com Dave Golden Sales Development – Mid-West dgolden@plainfieldprecision.com Chuck Pointer Sales Development – East Coast cpointer@plainfieldprecision.com 22
Questions ? Thank you