UNDERSTANDING THE USES AND BENEFITS OF IN-MOLD TECHNOLOGY AND AUTOMATEDMANUFACTURING CELLSPresented By:

Wade Clark, President/CEO

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.

• 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

Combination of two or more parts to

make an assembly inside the

injection mold, without the need of

external automation.

In-Mold Assembly

Types of assembly methods

• Snapped

• Riveted

• Inserted

• Screwed

• Pressed

• Bonded

Combined with Other Processes to Create Final

Component/Product.Some of these processes are:

• Stamped

• Coined

• Detached

• Decorated

• Closed

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

Other advantages• Creating a sub-assembly• Preparation for downstream process• Protection for part handling• Eliminate contamination

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?

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.

Highlights from

NPE:

In-Mold Components

The process…

has it changed?

Traditional Process:

In-Mold Process:

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

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

Initiate Ideas!

Ideas must be right,up front…

Accept ability to adapt!

Formation of a…

Training leads to…

KEYS TO SUCCESSManufacturing

Automation

Automationto remove labor and improve production

See what you can do!