weber automotive interior presentation

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ISO 9001 : 2008 Registered

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WEBER MANUFACTURING TECHNOLOGIES INC.

Tooling for Automotive Interiors

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COMPANY OVERVIEW

Founded in 1962, Weber Manufacturing Technologies Inc. is a leading manufacturer of precision tooling for Automotive, Aerospace, and Home/Building Products.

Located in Midland, Ontario, Weber offers high quality tooling in nickel, steel, invar and aluminum, and precision CNC machined aluminum parts.

Over the last 15 years, Weber has developed nickel shell tooling using the Nickel Vapor Deposition (NVD) process. This process is also used for capturing fine surface detail, such as leather and wood

grains, and authentically replicating them into hard tools.

135 employees, 135,000 sq. ft. facility

On-site CAD Design capable (UGS, CATIA)

Certified ISO 9001:2008

Canadian Controlled Goods Program registered

Modern simultaneous 5-Axis CNC machining centers

Full complement of CNC contour mills, gun-drills, vertical mills, and EDM machines

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PLANTS OVERVIEW

HEAD OFFICE, MOLD MANUFACTURING, AND NICKEL VAPOUR DEPOSTION

PLANT ALL LOCATED AT MIDLAND, ONTARIO, CANADA

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1962 Established Weber Manufacturing (Windsor) Limited

1967 Relocated to a new building in Midland, Ontario

Established the Weber Tool & Mold Division

1989 Established the Nickel Tooling Technology (NTT) Division

1991 Sold our first Nickel Shell

1998 Built and tested NVD Pilot Plant

1999 Designed and Built Large Scale NVD Plant

2000 Commissioned the NVD Nickel Division

2001 Produced our first Nickel Shell in February

2004 Company purchased by American Capital Strategies and TMB Industries

2007 Company purchased by Zynik Capital Corporation

COMPANY HISTORY

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Automotive Exterior Automotive Interior

Home & Building

Key Market Areas

Aerospace

Key

Market

Areas

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QUALITY CERTIFICATIONS

• ISO 9001:2008 certified

• Boeing Certified Supplier

• Registered with Canadian Controlled Goods Program - Registration No. 22921

• CWB W47.1, W59 Welding certificates

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�ISO 9001:2008 Certified

� 2 Computer Controlled 5-axis CMMs

� 3 Full Time CMM Operator/Inspectors

� Full Certification of Models, Tooling Aids,

Molds & Finished Parts to Math Data

� Steel Hardness Check on Incoming

Blocks

� Diffracto Class-A Surface Quality

Verification

� Detailed Inspection Reports sent to

Customer

� Mold Completion Check List

QUALITY ASSURANCE

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WEBER MACHINE CAPACITY

• 6 5-Axis CNC Mills

• 2 4-Axis CNC Mills

• 3 Vertical Mills

• 3 Tarus CNC Gun Drills

• 4 Horizontal CNC Boring Mills

• 5 Droop & Rein 3-Axis CNC Mills

• 2 EDM Machines

• 3 Various Detail Machines

• 2 Vertical Presses

• 2 CMM Measuring Machines

Weber has a total of 32 large CNC machines;

• Yag Laser Welder

• Thermal Spray

• Tig & Mig Welder

• ARC Welder

• Aluminum Oxide, Glass

bead and sand blasting.

Weber also has various welding and checking tools;

• Profilometer

• Hardness Testing

• Ultrasound Thickness Checking

• Thermal Imaging

• Laser Pyrometer

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EQUIPMENT HIGHLIGHTS

• State of the art machining.

• Hypermill 5- Axis software.

• 590 in/min max cutting speed

with 8,000-10,000 RPM.

• Machining aerospace parts

Five 5-Axis Deckel Maho Machining Centers

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Equipment Highlights

Ingersoll Master Mill

• 5-Axis simultaneous capable.

• 5 different cutting head

attachments. 4,000 -10,000

RPM. All automatically loaded

and unloaded.

• Large work envelope

• X-236 inches

• Y-137 inches

• Z-40 inches

• Table capable of taking 88,000

pound block.

• Utilizes HyperMill Machining

Software.

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AEROSPACE PART MACHINING

Boeing B787 wing components machined in Aluminum

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• World’s only commercial Nickel Vapor Deposition

facility

• Modern, computer controlled plant, built in 2000

• 4 Production chambers, 1 R&D

• 24 X 7 operation

• 400,000 lbs Ni deposition capacity

• 5.7’ X 9.8’ shell size capacity

NVD NICKEL PRODUCTION FACILITY

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• Deposition of Nickel from a vapour

creates solid nickel on the outside

surface of a heated mandrel, under

low pressure in a sealed chamber

• The mandrel is a precision, CNC

machined duplication (“master”), of

the desired shape and surface. It is

infinitely re-usable for duplicate nickel

shells

• Carbon monoxide given off by

the reaction is collected and

reused in a closed loop system.

NVD – DEPOSITION PROCESS

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Electroformed Nickel Shell NVD Nickel Shell

1. 0.25mm per 20 hr growth rate

2. Shell thickness is not uniform during growth

3. Inherent residual stresses

4. Cavities made simultaneously from different mandrels

5. Problematic variation - cavity to cavity

6. Replace damaged shell in 12+ 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

1. 0.25mm per 1 hr deposition rate

2. Uniform thickness during growth

3. Negligible residual stress

4. Cavities made sequentially from the same 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

9. No environmental impact (closed system)

COMPETITIVE PROCESS COMPARISON

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NICKEL VAPOUR DEPOSITION

• The re-usable deposition mandrel is placed in the NVD

chamber and heated to approximately 180 C.

• Nickel is deposited onto the mandrel at a rate of 0.010in (0.25 mm)/hr of thickness regardless of size

• Mandrel must be cleaned and prepared prior to each

deposition

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AUTOMOTIVE INTERIOR NICKEL TOOLING

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CUSTOMERS – OEM, TIER 1 & TIER 2

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IN HOUSE MASTERING & PATTERN SHOP

In-house Manufacturing of Wrapped Master Models.

Extensive Master Model Wrapping Experience with all Interior Components.

In-house Manufacturing and Seam Engraving of Hard Epoxy Master Models.

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RECENT PROGRAMS

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FORD C346 – FORD FOCUS

WEBER MANUFACTURED WRAPPED MASTER MODEL & THE FINAL EPOXY MASTER MODEL

SLUSH TOOLING – (15) 2-CAVITY TOOL SETS(6) SINGLE CAVITY TOOLS

(INCLUDING INTEGRATED POWDER SAVERS)

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JC49 – DODGE JOURNEY – LHD & RHD


12 LHD TOOLS– 6 RHD TOOLS

SPRAY TOOLING WITH INTEGRATED HEATING SYSTEM

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CHRYSLER LX (CHRYSLER 300)BOTH LHD & RHD FULL INTERIORS

IP, FRONT & REAR DOORS, LEFT & RIGHT CONSOLE PANELS


IP SLUSH TOOLING – 8 LHD IP TOOLS, 2 RHD IP TOOLS

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DODGE LD (DODGE CHARGER)

IP, FRONT & REAR DOORS, LEFT & RIGHT CONSOLE PANELS


SLUSH TOOLING – 8 LHD TOOLS

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BMW F25 – BMW X3 - LHD & RHD

WEBER MANUFACTURED WRAPPED MASTER MODEL SUBSTRATE & THE FINAL EPOXY MASTER MODELS

SLUSH TOOLING – 16 LHD TOOLS – 6 RHD TOOLS

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HIGH PRESSURE INJECTION MOLDS FOR INTERIORS

Nickel shells are mounted into

steel cavity shoes and fully supported for injection tooling.

PUR Overmold

Rim Overmold

BMW F07 – (BMW 5 SERIES)

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NEGATIVE VAC & IMG NICKEL SHELLS FOR INTERIOR

.008” VACUUM HOLES EVERY 10mm

FULL CONTROL OF HOLE PATTERN & SPACING

PRECISION PLACEMENT OF VACUUM HOLES IN THE VEIN DETAIL ONLY TO MINIMIZE VISIBILITY

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ADVANTAGES OF NICKEL VAPOUR DEPOSITION FOR NEGATIVE

VACUUM AND IMG AUTOMOTIVE TOOLING

ELECTROFORM POROUS

NICKEL EXAMPLE

NICKEL VAPOUR DEPOSITION

POROUS NICKEL EXAMPLE

VACUUM HOLE PLACEMENT ON NVD NICKEL SHELLS IS DONE PRIOR TO SHELL

DEPOSITION WITH FULL CONTROL OVER GRID DENSITY. PLACEMENT OF THE

VACUUM HOLES IS IN THE VEIN DETAIL GIVES SUPERIOR IMG SKIN RESULTS.

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NVD POROUS NICKEL SHELLS

HAVE THE SAME STRENGTH

AS NVD SHELLS WITHOUT

VACUUM HOLES

TYPICAL NVD POROUS NICKEL SHELL

VIEW OF SHELL SIDE & FRONT

VIEW OF SHELL BACKSIDE

NVD TEXTURED 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 MandrelCast Silicone onto

Mandrel

Nickel Vapour Deposition Process

Shell Stripping and Mold Assembly

Mold Inspection and Approval

Repeat Steps for Multiple Molds/Shells

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Inspection / ApprovalLWM CMM Inspection /

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Enhance Epoxy

Model Seam LinesCast Epoxy Master

Model

Epoxy Model CMM Commission / Inspection

Cast Silicone Negative from Epoxy Master

Build Silicone Support Mold

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PRECISION LASER WELDINGON SITE TEXTURE REPAIR SPECIALISTS

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ADVANTAGES OF NICKEL VAPOUR 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 VAPOUR 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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DESIGN CAPABILITIES

• Extensive CAD/CAM capabilities

• 8 workstations running:

• UG NX – Primary CAD Software

• IDEAS, Catia, Solid Edge and AutoCAD - used for translations

• Innovative designers work with customers to contribute to processes and provide tooling solutions.

• Our Design Team manages all project information and supports the Machining, Moldmaking and CMM teams.

• Strict Engineering Change revision control on all documents and designs to AS9100 standard

• Full time in-house IT Department for CAD/CAM/Network support

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CONTACTS

weber automotive interior presentation

Automotive

axis cnc mills

cnc contour mills

nickel shell tooling

vertical mills

horizontal cnc boring

nickel shell1998

nvd nickel division2001

axis cnc machining centersfull