understanding the uses and benefits of in-mold technology and automated manufacturing cells
DESCRIPTION
UNDERSTANDING THE USES AND BENEFITS OF IN-MOLD TECHNOLOGY AND AUTOMATED MANUFACTURING CELLS. Presented By: Wade Clark, President/CEO. Founded in 1988 with the focus on conventional EDM for the aviation and moldmaking industry. Built first mold in 1990. - PowerPoint PPT PresentationTRANSCRIPT
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UNDERSTANDING THE USES AND BENEFITS OF IN-MOLD TECHNOLOGY AND AUTOMATEDMANUFACTURING CELLSPresented By:
Wade Clark, President/CEO
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An Industry Leader.• Founded in 1988 with the focus on conventional EDM for the aviation and moldmaking
industry.• Built first mold in 1990.• Built first tool with In-Mold technology in 1995.• Built first tool with 3 individual molded assembled parts in 2001. • Electroform manufacturing has been automating and palletizing over ten years.
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• Electroform has made a considerable investment in Research & Development of in-mold and automated technologies.
• Clients come to us with complex projects. • We assist on part design, product
development.• Supply turn-key automated work cells.
Research & Development
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Combination of two or more parts to
make an assembly inside the
injection mold, without the need of
external automation.
In-Mold Assembly
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Types of assembly methods
• Snapped
• Riveted
• Inserted
• Screwed
• Pressed
• Bonded
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Combined with Other Processes to Create Final
Component/Product.Some of these processes are:
• Stamped
• Coined
• Detached
• Decorated
• Closed
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Advantages of In-Mold Assembly and Automated Manufacturing cells
• Better fit and performance.
• More consistent product
• Not subject to warp and shrinkage issues
• It enables you to find problems at the machine or cell not later in manufacturing process
• Part orientation (for In-Mold printing or decoration or assembly)
• Elimination of quality issues
• Saves on handling, inventory and logistics
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Other advantages• Creating a sub-assembly• Preparation for downstream process• Protection for part handling• Eliminate contamination
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Choosing a Supplier• Get supplier involved early in the development process• Does your supplier have processing capabilities?• Is your supplier capable of in-house training and support?• Does your supplier offer an assembly and preventative
maintenance manual?• Choose a supplier that has a good understanding of each
part of the process.• Do you trust your supplier?• Does your supplier offer a comparison of standard
automation vs. in-mold assembly?
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Prototype First• Make sure you choose right
materials for the application
• Prove capability and
functionality
• Molds and automation can be
very complex.
• Cost can be substantial once
process started.
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Highlights from
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NPE:
In-Mold Components
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The process…
has it changed?
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Traditional Process:
In-Mold Process:
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Traditional Molded and Assembled ProductThree Separate Molds: $210,960Three Presses one with Automation: $285,000Automation to Present the Film: $40,000Automation to Assembly the Car: $190,000Total: $725,960
In-Mold AssemblyOne Two-Shot Press with Robot: $285,000One Mold: $213,310System to Present the Film: $40,000Total: $538,310
Capital Savings with the In-Mold Process: $187,650
Case Study
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Injection Molded Piece Part Costs Without Film (Based on four million finished cars per year)
Press rate of: $70.00 per hour for 250 2-Ton Shot MachineWith .125 Operator at $25.00 per hourCycle Time: 15 secondsCost: $.126Press rate of $50.00 per hour each for 80-ton Molding MachinesWith .333 Operator at $25.00 per hourCycle Time: 10 seconds per moldCost: $.172 (cost does not include assembly)
Case Study
Total Cost Savings of In-Mold Assembly:$184,000 per year
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Initiate Ideas!
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Ideas must be right,up front…
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Accept ability to adapt!
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Formation of a…
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Training leads to…
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KEYS TO SUCCESSManufacturing
Automation
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Automationto remove labor and improve production
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See what you can do!