UNDERSTANDING THE USES AND BENEFITS OF IN-MOLD TECHNOLOGY AND AUTOMATED MANUFACTURING CELLS Presented 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 Built first tool with In-Mold technology in Built first tool with 3 individual molded assembled parts in 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 Product Three Separate Molds: $210,960 Three Presses one with Automation: $285,000 Automation to Present the Film: $40,000 Automation to Assembly the Car: $190,000 Total: $725,960 In-Mold Assembly One Two-Shot Press with Robot: $285,000 One Mold: $213,310 System to Present the Film: $40,000 Total: $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 Ton Shot Machine With.125 Operator at $25.00 per hour Cycle Time: 15 seconds Cost: $.126 Press rate of $50.00 per hour each for 80-ton Molding Machines With.333 Operator at $25.00 per hour Cycle Time: 10 seconds per mold Cost: $.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 SUCCESS Manufacturing Automation

Automation to remove labor and improve production

See what you can do!