Pioneering innovation: Hettich Business Unit

Innovative System Components (ISC)

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Innovative System Components

Innovative System Components: ISC

2 Development We follow a zero-defect strategy with project support every step of the way. This starts with concept definition and consulting, continues through the development and design phase and covers every stage in production and logistics. The entire portfolio for mechanical assemblies and compo-nents is also available to our customers.

3 PrototypingWe use cutting-edge rapid-prototyping techniques to produce models and functional prototypes of components and assemblies. This is done on state-of-the-art NC milling machines, stereo lithography apparatus, sheet-metal machining and vacuum casting facilities.

4 Tool and die makingOn 620 m² of floor space, a experienced 50-strong team oversees all of the processes involved in making tools. Project responsibility starts with importing data and continues with developing / optimising articles, designing tools, simulating mould filling, tool-making, sampling, measuring and testing and extends right through to releasing components and complex assemblies for serial production. Our tooling portfolio covers tools for plastic injection moulding, including complex hot runner

An idea evolves into a product We can provide anything from a simple component to a working module, from a plastic coated metal part to an extremely complex functional group. The process chain follows an approach that always focuses on both the customer and project. Specialising in the development and industrial production of high-quality components, assem-blies and systems at serial level, Hettich supplies prominent companies in key sectors of industry across the globe. Hettich is renowned as a flexible, efficient and creative partner with a track record of success stretching back many years in a demanding and challenging market. Covering the Innovative System Components (ISC) business units, we are a division of the Hettich Group with operations in Germany, the Czech Republic and Spain.

1Consulting For us, personal contact in consulting and customer service goes without saying. Experienced engineers, developers and expert business consultants turn requirement profiles into all-embracing solutions that cover every production factor from profitability analysis to logistics.

Innovative System Components:You produce systems. We supply the components.

PrototypingConsulting

Serial production

LogisticsCustomer

Quality assurance

Tool and die making

Development

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technology and tools for die-casting zinc and magnesium. Servicing, maintenance and repair ensures tool availability throughout the article life cycle

Tool design / New toolsWe assist our customers as early as the component development and project planning phase with the aim of optimising production engineering and minimising tool costs. Our modern machinery gives us the basis for quickly responding to challenging client demands. Intensive cooperation between our design, tool-making and production departments guarantee short throughput times, a high degree of flexibility and first-class quality. For our specialists, the constantly growing demands on quality, inventive spirit and an openness to new technologies are the driving forces behind advancing everything we produce.

Tool repair Pursuing a strategy of preventive and targeted maintenance, we ensure the availability of tools through-out their life cycle. Our dedicated and committed team also makes sure tools are repaired at any time during production - 24/7. This way, tools can be quickly restored to proper working order.

Quality assurance Quality management systems conforming to TS16949, environmental audits and EU environmental certification attest to state-of-the-art production facilities and methods of a high technical standard.

6 Serial production Using cutting-edge technologies and methods, we are committed to short process chains in production. With the aim of ensuring zero-defect production, items always remain in the correct position for several consecutive processing operations..

7 LogisticsBehind Hettich Frankenberg is the infrastructure of a global-playing company group with excellent communications and transport networks. Supply-chain reliability is based on a logistics network with competent local sourcing and procurement. Our warehouse and shipping staff work in 2 or, if necessary 3 shifts a day to meet customer demand. On 09.05.2011 we were awarded AEO status (Authorized Economic Operator) - customs simplifications/security - by the district customs office in Giessen. All kinds of pallets and packaging material can be stored and delivered.

We can provide you with the following services:

· Project management and coordination with internal and external service providers· Drawing up concepts with a variety of options· Rapid construction of initial 3D models to illustrate potential concepts· Working out detailed solutions for clip systems, latching, locking and sliding mechanisms· FEM calculations for verifying component design (static/dynamic)

· Generating production-level 3D CAD models and 2D drawings· Assembly packaging and collision studies· Tailoring your models for compatibility with tooling· Producing samples of products using all common prototyping methods· Defining tolerances in consideration of material and component properties· Consulting on material selection

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I n n o v a t i o n p r o c e s sConcept studies Development Detailed studies Realization Product launch

Technologies

Zinc/magnesium die-casting

We produce components and assemblies from zinc and magnesium die-castings. The services we offer our customers range from development, designing products suitable for die-casting as well as efficient project management support and extend right through to punctual initial sampling and serial production in the highest level of precision and quality.

In production cells, die-castings are picked off by robot, camera-checked for quality, deburred by punching and directly finished by sand-blasting, vibratory grinding or thermal deburring.

Our expertise lies in manufacturing thin-walled, complex functional and surface die-castings with tight tolerances and requiring no post-machining.

We can offer special processes, such insert moulding (insertion of steel parts), plastic sheathing of die-cast components and module assembly. Depending on require-ments, products are galvanised, passivated or cathodic dip painted.

Our staff are motivated and highly qualified. Our die-casting production is on the cutting edge of technology. It is on this basis that we manufacture products of the highest, constant precision and quality. Our multi-cavity tools let us guarantee 250,000 shots for magnesium and as many as 1,000,000 shots for zinc. In exceptional cases and depending on component geometry and surface requirements, service life can be far higher.

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Seven days a week, some 70 million precision injection mouldings are produced every month on 84 injection moulding machines with a clamping force of 70 to 4,500 kN. In addition to bulk plastics, the main materials used are engineering plastics, such as PA and POM as well as various high-performance plastics. This way, no less than approx. 4,000 tonnes of pellets are processed annually.

Grouped together in production lines, 20 fully automatic machine process individual components to produce complex assemblies for the automotive industry. These include systems for window lifts and glove-compartment locks.

Apart from conventional injection moulding, we employ special processes, such as assembly injection moulding (double stack turning technology), 2-component injection moulding and insert sheathing.

The established strategy of zero-defect production, e.g. involving the use of cavity pressure sensors, results in long-standing customer relations with satisfied partners on both sides..

Industrial injection moulding

As developers and producers of automatic assembly machines, we supply systems that always keep us a step ahead in assembling complex mechanical and electrical assemblies. Manual, semi-automatic or fully automatic assembly are the options we can give our customers. Camera-assisted quality inspection, fully automatic function testing and integrated packaging complement our service portfolio

Assembly technique

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Strategic product groups: Housing assistance systems

Central displays in magnesium

Driven by legislation to reduce CO2 and the resultant need to save weight, housing or support systems for navigation systems and instrumentation have become established that are made of magnesium. Besides low weight, benefits also include the ability to produce thin walls - made possible by the hot-chamber die-casting technique - while at the same time optimising electromagnetic screening and heat dissipation. The use of high-purity AZ91HP alloy obviated the need to add corrosion inhibitors.

EMC shield - Screening for lane-change assist system

This corrosion-proof component provides electromagnetic screening between radar aerial and the electronic components of a lane-change assist system.

Display rear panel for split view monitor

This large, thin-walled component provides the housing for a split-view monitor. Perfect evenness avoids any shadow effects on the display.

1st place2013 Component Award from EFM European Research Association for Magnesium Automotive Category

3rd place2013 Component Award from EFM European Research Association for Magnesium Automotive Category

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Tailgate drive for cars and SUVs

Car and SUV tailgates can be opened and closed auto-matically with an innovate drive unit. The compact drive system unit is accommodated in an housing with cover. These parts are die-cast. The magnesium components are designed to take account of limited package and the extremely high levels of stress they are exposed to. The close tolerances of the bearing seats prevent wear and give the drive unit the length service life demanded.

Mobile data recording

Powder coated magnesium housing for mobile data logger. Impact-resistant, waterproof and dust-tight to protect against ambient conditions. Our work operations: casting, powder coating, integration (bonding) of bluetooth aerial, wi-fi window, lock seal and optical fibre.

Display rear panel - freely programmable instrumentation

This magnesium housing is used in the field of automotive instrumentation. Fine markings integrated in the casting process facilitate camera-assisted assembly and ensure exact component alignment.

3rd place2011 Component Award from EFM European Research Association for

Magnesium Non-Automotive Category

1st place2012 Component Award from EFM European Research Association for Magnesium Automotive Category

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Strategic product groups: Lightweight support systems / Sliders, hinges and fasteners

Guide slider and hinge for centre armrest

Adaptations from technology for furniture also provide functions for applications in the motor vehicle. In this example for providing the centre console arm rest with horizontal and vertical adjustment capabilities.

Sliders, hinges and fasteners

Plastic latching assembly for centre armrest

Modular system for locking the centre armrest for ECE and with additional rollover safety catch (ball sensor) for the US market.

Lightweight support systems

Instrument panel support in magnesium

Instrument panel support in 3-part modular design comprising supports for the driver side, centre and front-passenger side. Components are stamped, blast-deburred and premounted.

Lightweight support element for the centre console

Support for armrest with cathodic dip painted surface.

2nd place2013 Component Award from EFM European Research Association for Magnesium Automotive Category

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Functional components in zinc

Crank pins for window lift systems

Crank pins are standard components in window lift systems and needed in large quantities. Manufacturing crank pins in zinc alloys using the hot-chamber die-casting process has proven its worth in meeting the demands that are placed on mechanical properties, dimensional accuracy and price. Complicated in terms of casting and tool engineering, these are high-quality working components for automotive platform solutions.

Functional components for exterior door handle

Functional components for the exterior door handle comprising mass locking mechanism, mass-balancing weight and a plastic coated deflection lever.

Strategic product groups: Dipoles / Functional components in zinc

Dipoles

Dipoles are used as functional components in mobile cellular radio aerials. Their size defines the aerial‘s frequency range.

The processes we use in zinc die-cast allow us to provide even the most complex and delicately structured geometries for medium and large-scale serial manufacturing. This is why we are development partner to market‘s leading company in this product sector.

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Reference customers

· Bosch

· Brose

· Continental AG

· Daimler AG

· Dräxlmaier

· Dr. Schneider

· Eissmann Automotive

· Grupo Antolin

· Katek

· Kathrein

· Key Plastics

· Küster ADS

· Magna

· Magneti Marelli

· SATA

· Siemens

· Tyco Electronics

· Vectron

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· SATA

· Siemens

· Tyco Electronics

· Vectron

Our operations

Germany:Hettich Druck- und SpritzgussZinc and magnesium die-cast, injection moulding, assemblies

Spain:Stamping and assembly

Czech Republic:Zinc die-cast, injection moulding, assembly, modules

Druck- und SpritzgusswerkHettich GmbH & Co. KGSiegener Str. 3735066 Frankenberg

Telefon +49 6451 741-0Fax +49 6451 741-200hds.info@de.hettich.comwww.hettich.com/isc

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