1. Thinking in MuCell January 2012

2. Plainfield Precision - MuCell
User of MuCell since 2000
Multiple MuCell Machines in high volume production
since 2002
Currently have Seven (7 ) MuCell machines
125 to 500 tons
Three are rotary / Insert molding machines
Perform mold trial services / sampling

3. 50+ Years of Experience Company Overview Capabilities:
Injection Molding: (18 to 500 Tons) ,complex insert, two-shot, precision, mu-cell and reel to reel molding
Metal Stamping: (30 to 200 Tons), multi-slide components, pad printing, coil winding, contract riveting and welding
Assembly: Automated and Manual
5 manufacturing plants worldwide:
United States (3), Mexico, Dominican Republic
Industries: Medical, Automotive, Consumer, Aerospace, Military, Electronics, Commercial

4. Core Capabilities Metals (stamping, multi-slide) Plastics
(Injection molding)
Value Add
Insert molding & automated insert molding
Assembly & testing

5. Locations Sturgeon Bay, Wisconsin, USA
Precision Stamping, Multi-Slide, Pin Bandoliering and automated assembly Insert molding
Plymouth, Massachusetts, USA
Engineering Development Center. Insert, MuCell and Precision Molding, Pad Printing, Automated Assembly
Santo Domingo, Dominican Republic
Precision Molding, Pad printing, Lens molding and assembly
San Luis Potosi, Mexico
Insert, Two-Shot and Precision Molding, Pad Printing and Assembly
Plainfield, Illinois, USA
Precision Molding, Thermoset Molding, Pad Printing and Assembly 5

6. Plainfield Precision - Locations
Sturgeon Bay, WI
Plymouth, MA
Plainfield, IL
Irvine, CA
Santo Domingo, DR
San Luis Potosi, MX

7. MuCell for Unique Solutions Our experiences go beyond
“Weight Reduction”

8. Air Meter 2003 GM GMT 610 Platform
2002 SPE Automotive Innovation Award Winner
Category: Process / Enabling Technologies
MuCell Benefits
Superior thermal fatigue properties vs solid
Eliminated sink marks
Significantly reduced warpage
Improved Dimensional Stability
12% weight reduction
Air Flow Meter Flow Tube and Carrier
Material: Celanex 6500 PBT
Glass-fiber/mineral-filled

9. Hot runner valve gates used Reduced warpage Improved assembly fit
Air Flow Tubes
First mold initially built for solid material, ran in MuCell without changes
5 different tubes, 8 molds
Hot runner valve gates used
Reduced warpage
Improved assembly fit
12 % weight reduction
30% cycle time savings
Reduced time to market (debug time)

10. Tube – Warpage

11. Tolerances – Large Inner Diameter

12. Air Meter
Sink Area
Flat

13. Generation1.3 Air Meter 2-3% weight reduction
Eliminated sink, distortion and warpage in thick wall
Reduced distortion of connector
Reduced flash
MuCell enabled us to fill “tab” area of part

14. Air Meter
MuCell
Solid

15. Generation 1.5 Air Meter
Two-shot, insert molded, Pre-mold/Overmold process
Insert molded pre-mold is molded using MuCell
Results:
10% weight reduction
Minimal flash at shutoff areas compared with standard molding
Reduced chance of insert movement during molding
20 % Cycle time reduction*
*excluding insert load time

16. Minimal Flash
30X magnification – minimal flash (leak) at critical “shutoff” areas

17. Insert Molding Advantages
Small traces, tight spacing
Very Sensitive to molding pressures
Traditional high pressure molding causes electrical shorts

18. Junction Connector Block
Process Flow
Stamping,
Assembly of stamping to “pre-molded component
Overmolding
MuCell utilized to resolve “leakage “issues
Part was not designed for MuCell
Polymer is Nylon 6/6, 40% glass filled
Component must pass USCAR Class IV requirements
Other benefits:
Cycle time
Part weight

19. Junction Connector Block
12.5% weight reduction
Cycle time reduction 30 to 25
Hold time from 6 to 0.5
Inj time from 1.2 to 0.4
Mold open/close 0.5 less (lower hydraulic pressure)
Material: Nylon 6/6
Problem: water leakage past substrate interface
Solution: MuCell allowed faster fill which created tight seal around substrates
Saved $215/day in material
Able to produce 2100 more pieces per day

20. Overall MuCell Experiences
Cycle time savings – in most cases
Reduced tonnage required – in most cases
More uniform shrinkage (less distortion, sink, warp) – in all cases
Reduce leakage – improved seal around substrates
Material reduction – in most cases
Benefits from Low cavity pressure – where applicable
Minimized distortion around insert molded substrates
Additional variable in process
Training
Maintenance – replacement parts 20

21. Future MuCell Growth at Plainfield Precision
Why?
We have a developed competency
Existing equipment
Years of Knowledge of process and tooling
Differentiation to our customers
MuCell solves problems and lowers part cost
Investment cost for MuCell continues to drop – ROI
Complementary technology to insert molding
How?
Expand Equipment range and type – more machines
Quote as cost saving option
Weight savings, cycle time, etc.
Solve technical problems (with indirect cost savings)
Always ask “Why not?”

22. Key Business Development Contacts
Plainfield Precision
Key Business Development Contacts
Key Contacts
Position
Seth Christian
VP Sales & Marketing
Jonathan Soucy
President, Advanced Technology Group
Ian Macleod
Vice President, Technology
Rob Kretzmer
Sales Development – West Coast
Dave Golden
Sales Development – Mid-West
Chuck Pointer
Sales Development – East Coast 22

23. Questions ?
Thank you