Feasibility Study Report Nokia Dilbert A-cover assembly Based on 3D files received on Version: v0.1

2 General Project name: Customer: PCC Site / Design center: Project type:copy, mfg, Design, R&D, ? Type of Product:e.g. slider / watch Ramp-up: Customer LOM Period / Year / Location Lifetime:# months Customer plant focus: LOM plant focus: Volumes: Total volume Global peak volume Number of sales items / assemblies Needed technologies

3 Feasibility Study Summary Feasibility Study Summary is documented on separate excel –file Copy-paste here a screen shot from Feasibility Study Summary –excel You can also add here a link to the Summary –excel that is stored in project database

4 A-cover assembly – xx xx –xx xx – xx xx General Assy Information #1 A-Cover Gasket uplink mic lower Display window assembly A-cover welded assembly Gasket display Qwerty domesheet assembly Gasket uplink mic upper Qwerty fpc assy

5 A-cover welded assembly – A Cover Bezel xx –A Cover Frame & screw bosses xx – A Cover Support Xx – A Cover Grounding Strip xx Sub Assy #1.1 A-Cover Welded Assembly A-cover grounding strip A-cover frame A-cover support A-cover bezel

6 Part Name: A-cover frame Part 3D Version: Material: SUS 304 1/2hard s=0.3mm Weight / Vol.104mm x 58mm x 2.4mm Secondary Operations:Laser Welding Main Technologies:Deep Drawn General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx Thread insert 4pcs

7 Metal tools costing & tooling data and feasibility study Project / part name:Dilbert / A-Cover frame Customer name: Nokia Date: Author: Ari Piipponen

8 A-COVER FRAME Strip & material information: Based on file date: Raw material: SUS 304 1/4H Thickness: 0,3mm Width: 150mm Step length: 80mm Scrap: 68%

9 A-COVER FRAME Punching direction. Rolling direction: Progressive tool information: Cavity No: 1 Module type: China Module quantity: 3 Steps on tooling: 9 Out of tool: Bulk Punching press: Aida 1600 Strike speed: 60 pcs/min Steps of the tooling: Step #1: Blank cutting Step #2: Blank cutting Step #3: Blank cutting Step #4: Blank cutting Step #5: Deep drawing Step #6: Part cutting Step #7: Part cutting Step #8: Empty step Step #9: Part detaching Step #10: Step #11: Step #12: Step #13: Step #14: Step #15:

10 A-COVER FRAME Punching direction. Transfer tool-1 information: Cavity No: 1 Module type: St Transfer tool 50x450x450 Module quantity: 1 Punching press: Sino Strike speed: 12 pcs/min Steps of the tooling: Step #1: Part side cutting Step #2: Step #3: Step #4: Step #5: Step #6:

11 A-COVER FRAME COMMENTS Corner radius 0.2 needed all sharp corners

12 A Cover Frame Overview Material:  SUS304 ½ H T=0.3 Process:  Progressive Punching -> Side Cutting -> Washing -> Laser Welding No issue found

13 A Cover Bezel Assembly Review Issues Material thickness of A Cover Bezel is 0.4mm and thickness of A Cover Frame is 0.3mm, so there would be some welding marks on visual surfaces of C Cover, especially marks can be noted on polished surface with reflection. Suggestion 1.Option 1: Suggest to change thickness of A cover bezel from 0.4 to 0.5 mm 2.Option 2: Suggest to change thickness of A cover frame from 0.3 to 0.2mm, or only reduce welding area thickness of A cover frame to 0.2 by chemical etching

14 A Cover Bezel Tool Concept Review Side cutting 1 Side cutting 2 Suggest to adopt round cutting for this tool Issue In tool feasibility study report, A Cover Bezel is made by one progressive tool and two sets of side cutting tool. Suggestion To get better quality and easier to do Side Cutting 2, suggest to use Round Cutting for first transfer tool which will remove all flange caused by deep drawing.

15 Part Name: Qwerty FPC Assy Part 3D Version: Material: XXXX Weight / Vol.XXXX Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx Finger Print Sensor

16 Part Name: A-cover bezel Part 3D Version: Material: SUS 304 0hard s=0.4mm FinishPolished Weight / Vol.97mm x 59mm x 3.6mm Secondary Operations:PVD,.. Welded to Frame Main Technologies:Deep Drawn General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

17 Metal tools costing & tooling data and feasibility study Project / part name:Dilbert / A-Cover bezel Customer name: Nokia Date: Author: Ari Piipponen

18 A-COVER BEZEL Strip & material information: Based on file date: Raw material: SUS 304 1/4H Thickness: 0,4mm Width: 165mm Step length: 90mm Scrap: 93%

19 A-COVER BEZEL Punching direction. Rolling direction: Progressive tool information: Cavity No: 1 Module type: China Module quantity: 3 Steps on tooling: 9 Out of tool: Bulk Punching press: Bruderer 50 Strike speed: 60 pcs/min Steps of the tooling: Step #1: Blank cutting Step #2: Blank cutting Step #3: Blank cutting Step #4: Blank cutting Step #5: Deep drawing Step #6: Part cutting Step #7: Part cutting Step #8: Part cutting Step #9: Part detaching Step #10: Step #11: Step #12: Step #13: Step #14: Step #15:

20 A-COVER BEZEL Punching direction. Transfer tool-1 information: Cavity No: 1 Module type: St Transfer tool 50x450x450 Module quantity: 1 Punching press: Sino Strike speed: 12 pcs/min Steps of the tooling: Step #1: Part side cutting Step #2: Step #3: Step #4: Step #5: Step #6:

21 A-COVER BEZEL Punching direction. Transfer tool-2 information: Cavity No: 1 Module type: St Transfer tool 50x450x450 Module quantity: 1 Punching press: Sino Strike speed: 12 pcs/min Steps of the tooling: Step #1: Part side cutting Step #2: Step #3: Step #4: Step #5: Step #6:

22 A-COVER BEZEL Punching direction. Punching tool-1 information: Cavity No: 1 Module type: Chaina Module quantity: 1 Punching press: Sino Strike speed: 12 pcs/min Steps of the tooling: Step #1: Part cutting Step #2: Step #3: Step #4: Step #5: Step #6:

23 A Cover Bezel Process Overview Option 1 Process Flow (Refer to Victoria) Progressive Punching-> Round Cutting -> Side Cutting -> Window Cutting -> Washing -> Laser Welding ->Manual Polishing - >Washing -> PVD Advantage: 1.Dimension change will be small during polishing Disadvantage: 1.Scrap cost will be high if the defects from raw material or process before polishing are not capable to be removed Material: SUS304 O T=0.4 Polishing +PVD

24 Option2 Process Flow Progressive Punching -> Round Cutting 1 -> Side Cutting 2 -> Manual Polishing ->Washing ->Window Cutting (with foil) -> Laser Welding => PVD Advantage 1.Dimension change is small while polishing 2.Lower manufacture cost Risk 1.Scratches and dents would occur on polished surface caused by window cutting 2.There might be punch alignment issue which may cause overcutting or big burrs. A Cover Bezel Process Overview

25 Option 3 See next Page A Cover Bezel Process Overview

26 Option 3 Process Flow Progressive Punching -> Round Cutting 1-> Side Cutting 2 -> Window Cutting -> Manual Polishing -> Washing -> Remove Connecting Feature Manually or by jig -> Laser Welding -> PVD Advantage 1.Small dimension variation in polishing process. 2.Lower manufacture cost. 3.No punching after polishing, so no scratches and dents occurs. Risk 1.Minor steps on connecting area. Remarks 1.After window cutting, the connecting place will not be cut through to reinforce part for polishing process. After polishing, they can be removed manually or by jig because deep V-cutting exist at connecting area. A Cover Bezel Process Overview

27 Part Name: Grounding strip Part 3D Version: Material: SUS 301 H s=0.1mm Weight / Vol.34mm x 6.4mm x 0.7mm Secondary Operations:Heat stacked to B Cover (no plating required) Main Technologies:Stamping General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

28 A-cover Support – xx xx –xx xx – xx xx Sub Assy #1.11 A-Cover Support A-cover support plastic A-cover support metal

29 Plastic Material: LCP Sumitomo E6808 or Cycoloy C4 Shrinkage: ? Gate type: ? Plastic Metal A _Cover _Keypad _Support Suggest to the metal insert locate core side.

30 Part Name: A-cover support metal Part 3D Version: Material: SUS 304 1/2hard s=0.2mm Weight / Vol.52.4mm x 40.8mm x 2.1mm Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

31 Metal tools costing & tooling data and feasibility study Project / part name:Dilbert / A-Cover support metal Customer name: Nokia Date: Author: Ari Piipponen

32 A-COVER SUPPORT METAL Strip & material information: Based on file date: Raw material: SUS 304 1/4H Thickness: 0,2mm Width: 150mm Step length: 72mm Scrap: 67%

33 A-COVER SUPPORT METAL Punching direction. Rolling direction: Progressive tool information: Cavity No: 2 Module type: China Module quantity: 4 Steps on tooling: 12 Out of tool: Bulk Punching press: Bruderer 50 Strike speed: 80 pcs/min Steps of the tooling: Step #1: Blank cutting Step #2: Blank cutting Step #3: Blank cutting Step #4: Blank cutting Step #5: Blank cutting Step #6: Deep drawing Step #7: Part cutting Step #8: Part cutting Step #9: Part cutting Step #10: Part bending Step #11: Part bending Step #12: Part detaching Step #13: Step #14: Step #15:

34 A-COVER SUPPORT METAL Punching direction. Transfer tool-1 information: Cavity No: 1 Module type: St Transfer tool 50x450x450 Module quantity: 1 Punching press: Sino Strike speed: 12 pcs/min Steps of the tooling: Step #1: Part side cutting Step #2: Step #3: Step #4: Step #5: Step #6:

35 A-COVER SUPPORT METAL Punching direction. Transfer tool-2 information: Cavity No: 1 Module type: St Transfer tool 50x450x450 Module quantity: 1 Punching press: Sino Strike speed: 12 pcs/min Steps of the tooling: Step #1: Part side cutting Step #2: Step #3: Step #4: Step #5: Step #6:

36 A Cover Support Metal Process Overview Material SUS304 ½ H T=0.2 Process Progressive Punching -> Side Cutting 1 -> Side Cutting 2 -> Washing -> Insert Molding Remarks No issue found

37 Part Name: A-cover support plastic Part 3D Version: Material: LCP Weight / Vol.0.60cm^3 Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

38 Demoulding analysis Draft analysis (cav) Green surface need draft angle 3deg on the cavity side A _Cover _Keypad _Support

39 Demoulding analysis Draft analysis (core) Green surface need draft angle 1deg on the core side. A _Cover _Keypad _Support

40 Injection scheme/Gate location A _Cover _Keypad _Support Tunnel gate : Dia 0.8

41 Parting line A _Cover _Keypad _Support Red line is PL core cavity

42 A _Cover _Keypad _Support Remarks and open issues Thin steel, propose modify Before change After change

43 A _Cover _Keypad _Support Remarks and open issues Sharp steel, propose add R Before change After change

44 A _Cover _Keypad _Support Remarks and open issues 封胶位在铁片的 R 处，精度比较难 控制，建议修改 The material is ate the R of metal so that it’s hard to control the accuracy, suggest to modify. Before change After change

45 A _Cover _Keypad _Support Remarks and open issues Propose modify the dia of hole from 1.5 to 3.0 Propose modify the dia of hole from 1.5 to 3.5

46 A _Cover _Keypad _Support Remarks and open issues According to red line add draft angle for cavity side and core side

47 A _Cover _Keypad _Support Propose added holes show above picture Keep the metal touch core side when mould closed.

Part NameA-Cover SupportMaterialPC-ABS+GF, LCP+GF Project NameDilbertCustomerNokia AnalystSami VauhkonenDate25/09/2009 Flowsimulations

49 FEM and Process Parameters Moldflow MPI 6.2 (revision 3) Plastic Raw Material: Cycoloy C4220 & Vectra E130i (Sumitomo material data not available) Insert Raw Material: material SUS304 (Liteonmobile) Moulding process: Insert Moulding Process Wall Thickness variation: average, local massive sections at rib base Gate type: Tunnel gate Middle Gate

50 Filling: Injection Pressure Pressure level at switch point is low and acceptable on both versions Cavity pressure level at switch point LCP 200 Bar PC-ABS+20GF 480 Bar

51 Filling: Weld Lines & Wenting Main weld line locations as shown below Proper venting needed on highlighted areas No major filling based problems predicted Slight flow front hesitation on marked area (cause: thin section near gate) Hesitation is stronger with PC-ABS+GF due to higher viscosity See also the filling animation(s) hesitation LCP PC-ABS+GF

52 Packing: Frozen Layer Fraction LCP material freezing rate is very fast LCP part is totally frozen at 1,5 seconds  no packing problems PC-ABS material freezing time is about 5 seconds Gate is frozen at 3 seconds  massive sections will freeze without pressure PC-ABS+GF risk of VQ problems on massive ribs

53 Packing: Volumetric Shrinkage LCP no packing problems predicted LCP no Visual Quality problems predicted PC-ABS+GF volumetric shrinkage variation is slightly high on ribs and massive sections at corners PC-ABS+GF No dramatical risk of sink marks due to good pressure affection in cavity and 20% fiber content on material PC-ABS+GF Well aimed process optimization required to avoid VQ problems PC-ABS+GF

54 Deformations Maximum Z deformation on plastic part –LCP 0.3 mm –PC-ABS+GF 0.19 mm Flatness on plastic part –LCP 0.2 mm –PC-ABS+GF 0.12 mm Actual flatness values depends on measuring point locations There should not be dramatical dimensional problems

55 Cycle Time Insert Moulding Process PC-ABS+SUS304 Mould Closed Time: 5 seconds Mould Open Time: 6 seconds Difficulty Level: 2 second(s) Estimated Cycle Time: 13 seconds (fully automatic process) LCP+SUS304 Mould Closed Time: 2 seconds Mould Open Time: 6 seconds Difficulty Level: 2 second(s) Estimated Cycle Time: 8 seconds (fully automatic process)

56 Comments & Potential Risks No fillling problems predicted Switchpoint pressure level is low and acceptable LCP: No packing problems predicted No obvious VQ risks predicted PC-ABS+GF: Packing effeciency is not good on birs and massive sections Long freezing time compared to LCP material Process optimization required to avoid VQ problems LCP is dimensional stabile material, low linear shrinkage There should not be dramatical dimensional problems with this part Cycle time will be more cost effective with LCP material Material cost is much higher on LCP compared to PC-ABS LCP material painting is very challenging

57 Display window assembly – xx xx –xx xx – xx xx Sub Assy #1.2 Display window assembly Acoustic mesh earpiece Capacitive sensor and flex Assy. Window adhesive Window

58 Part Name: Window Part 3D Version: Material: XXXX Weight / Vol.2.46cm 3 Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

59 Part Name: Capacitive sensor Part 3D Version: XXXX Material: XXXX Weight / Vol.XXXX Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

60 Part Name: Flex Capacitive Sensor Part 3D Version: XXXX Material: XXXX Weight / Vol.XXXX Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

61 Part Name: Window adhesive Part 3D Version: Material: XXXX Weight / Vol.57.1mm x 54.3mm x 0.25mm Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

62 Part Name: Acoustic mesh earpiece Part 3D Version: Material: XXXX Weight / Vol.17mm x 5mm x 0.3mm Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx Adhesive Decorative mesh Adhesive Mesh

63 Qwerty domesheet assembly – xx xx –xx xx – xx xx Sub Assy #1.3 Qwerty domesheet assembly Domes Pet layer 1 Pet layer 2 Led reflector pads Thinfilm lightguide Lightguide adhesive

64 Part Name: Led reflector pads Part 3D Version: Material: XXXX Weight / Vol.XXXX Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

65 Part Name: Thinfilm lightguide Part 3D Version: Material: XXXX Weight / Vol.54.2mm x 41.4mm x 0.2mm Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

66 Part Name: Lightguide adhesive Part 3D Version: Material: XXXX Weight / Vol.XXXX Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

67 Part Name: Pet layer 1 Part 3D Version: Material: XXXX Weight / Vol.XXXX Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

68 Part Name: Pet layer 2 Part 3D Version: Material: XXXX Weight / Vol.XXXX Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

69 Part Name: Domes Part 3D Version: Material: XXXX Weight / Vol.XXXX Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx

70 Qwerty FPC assembly Sub Assy #1.4 Qwerty fpc assembly Finger Print Sensor

71 Part Name: Gasket display Part 3D Version: Material: XXXX Weight / Vol.55.5mm x 51.8mm x 1.9mm Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx Adhesive Gasket Adhesive Gasket

72 Part Name: Gasket uplink mic lower Part 3D Version: Material: XXXX Weight / Vol.7.4mm x 7.2mm x 0.8mm Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx Adhesive Foam

73 Part Name: Gasket uplink mic upper Part 3D Version: Material: XXXX Weight / Vol.5mm x 3.2mm x 0.96mm Secondary Operations:XXXX Main Technologies:XXXX General Part Information Major Risks Identified 1.xx 2.xx 3.xx 4.xx 5.xx Foam Adhesive Dust mesh Adhesive

74