Lean: From Theory to Practice — One City’s (and Library’s) Lean Story… Abridged
Aerospace
1. www.webermfg.ca
ISO 9001 : 2008 Registered
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WEBER MANUFACTURING TECHNOLOGIES INC.
Precision Tooling for Aerospace Composites
1 Tom Schmitz
2. www.webermfg.ca
ISO 9001 : 2008 Registered
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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 is a privately held Canadian company. Weber offers high
quality tooling in steel, invar and aluminum, and precision CNC machined aluminum parts.
Over the last 20 years, Weber has offered 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.
140 employees, 135,000 sq. ft. facility
Certified ISO 9001:2008
Canadian Controlled Goods Program registered (Satisfies US-ITAR requirement)
On-site CAD Design capable (UGS, CATIA V5R20)
Modern simultaneous 5-Axis CNC machining centers
Full complement of CNC contour mills, gun-drills, vertical mills, and EDM machines
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TOOLING MATERIALS www.webermfg.ca
Weber offers a range of materials to meet your Tooling requirements
• Invar
• Steel
• Aluminum
• NVD Nickel Shells
• High density foam
• Reinforced epoxy Welded Invar 36 tool
• Welded fixture construction
Aluminum and Nickel: tools and parts
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AEROSPACE
www.webermfg.ca
APPLICATIONS
• Examples of aluminum or steel matched molds for press
molding of interior Aerospace panels
• Ask for the Weber presentation on high pressure SMC
tooling or Automotive interior tooling
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AEROSPACE ISO 9001 : 2008 Registered
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APPLICATIONS
LAY-UP TOOLING
• Weber is a Boeing Approved Tool Supplier
• Nickel tools for high temp Polyamides
in F414 engine
• Nickel tools for B787 leading edge of vertical stabilizer
• Process at ~300 Celsius (600F)
• Nickel Lay up tools for Black Hawk UH60M
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TOOLING PACKAGE - BOEING 787
300 tools = Lay-up Mold’s, Trim & Drill Fixture’s and Hot Drape Form Tools
(Invar, REN Board and Aluminum)
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TOOLING PACKAGE – HONDA JET
Over 150 Lay-up Mold’s and Trim & Drill Fixture’s
(Invar, and Aluminum)
Full design in Catia V5 - from customer part model file – to tool and fixture drawing packages
KEY MARKET
AREAS 7
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FIXTURES and MODELS – DIAMOND JET
• Aluminum / REN bond tools, fixtures and prototypes
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FIXTURES and MODELS – BELL HELICOPTER
• Aluminum prototypes for
• Welded and machined 407 bonding fixture
• Production assembly
fixtures for windscreen
• ‘Soft’ Master models
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MACHINING FIXTURES
A2C2 Double Vane A2C2 Single Vane
Machine Fixture Machine Fixture
A2C2 Doublet Bond
Fixture
220 Inches
Aerospace Machining Fixture With
Vacuum Holding
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11. www.webermfg.ca
ISO 9001 : 2008 Registered
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Machined Aerospace Components
Various Aluminum Components Machined
for the Aerospace Industry By Utilizing One
Of Our Many 5 Axis CNC Machines
B787 wing components in machined aluminum
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AUTOCLAVE PACKAGES
Boeing 717
• 24 Lay-up Mold’s in NVD Nickel
• 6 - 8mm thick nickel shells mounted
onto steel weldment with adjustable
push/pulls
Bell Helicopter
• 407 Fuselage
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13. www.webermfg.ca
ISO 9001 : 2008 Registered
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Example of INVAR
lay up tool for
deep part
Close up of
INVAR
surface finish
quality
CAD design for
welding 5 pre-
shaped sheets
together on frame
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AEROSPACE
www.webermfg.ca
APPLICATIONS
Bell 429
Completed nose
cone tool and
frame
+120 other tools
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15. www.webermfg.ca
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Nickel Shell Application NVD Nickel Lay up tool for high temp
Polyimides >300 Celsius (600F process)
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•Encapsulations for vacuum
Nickel Shell Design through the shell
•No welding of the shell to the frame.
•Perimeter standoffs are pre-machined as
round counter-bored blanks and placed on
deposition mandrel.
•The shell is placed on the welded frame and
screwed into position.
•Encapsulations for tooling holes
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Shell Design - View through side cutout window
NVD Shell
Frame
Push Pull
Support
Spot
Welded
Studs
Vacuum
Line
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Rate tools in NVD Nickel from 1 Mandrel
MIDDLE CONSOLE MOLD (R-CLASS)
IP LOWER DRIVER MOLD (M-CLASS)
FRONT ARMREST MOLD (A-CLASS)
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PRESS TOOLING
Pratt and Whitney PW4168
• Acoustic Panel Sections
Innovative Weber tool design
Multiple parts and steel tools
• Tools mold-in >3700 holes
into the part
• Inspection fixture and preform tools
also supplied by Weber
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20. www.webermfg.ca
ISO 9001 : 2008 Registered
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RTM PROCESS – PRATT & WHITNEY
Pratt F117-PW-100 engine for C-17
•Jet fan splitter
•Large round multi-piece tooling
•Updated manufacturing process
•Reverse engineering to confirm existing drawings
•Integrated Oil heated design to eliminate ovens
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21. www.webermfg.ca
ISO 9001 : 2008 Registered
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RTM PROCESS – PRATT & WHITNEY
Pratt F117-PW-100 engine for C-17
•Jet fan spinners
•Round multi-piece tooling
•Updated manufacturing process
•Reverse engineering to confirm
existing drawings
•Integrated Oil heated design to
eliminate ovens
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RTM PROCESS www.webermfg.ca
• closing an RTM tool with integral cooling lines
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OUT OF AUTOCLAVE
See separate presentation
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NVD OPERATIONS
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ISO 9001 : 2008 Registered
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NVD NICKEL PRODUCTION FACILITY
• World’s only commercial Nickel Vapor Deposition
facility
• Modern, computer controlled plant, built in 2000
• 400,000 lbs annual Ni deposition capacity
• NVD nickel is 99.98% pure
• 1.74m X 3m shell size capacity
• Speed is 0.25mm per hour, 6mm in 1 day.
• Superior process to Electroformed Nickel
Chemically convert nickel to solid shapes
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26. www.webermfg.ca
ISO 9001 : 2008 Registered
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NVD SHELL TOOLING FEATURES
- NVD shell tooling - high strength and lightweight
- Flexible tool design options including:
• Undercut geometry
• Encapsulated features for mounting and
location, injection, ejection, shear edges,
mechanisms, etc
• Welded shell construction for very large parts
- For Multiple Molds, Replicate Cavities:
• Are identical
• Cost less than alternative machining
• Are easy to replace if damaged
• Replacement timing is weeks
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ISO 9001 : 2008 Registered
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NVD SHELL BASED TOOLING OFFERS…
• Conformal Heating/Cooling -> Faster cycle time
• Uniform nickel shell wall thickness -> Improved thermal distribution
• Mold release -> Fine grain structure
• Mold durability -> 34 – 38 Rc hardness
• Weldability –> allows for repairs or joining of multiple shells
• Fast Process (0.25 mm/hr) -> ¼” in 1 day !
• Reusable mandrel for duplicate shells -> Repeatable accuracy
• Short duplicate shell delivery times -> ~ 2-4 weeks
• Significant cost savings for duplicate shells
• CNC Machined Metallic Mandrels -> Accurate shells, greater part quality
• NVD Shells are virtually stress free -> Accurate shells
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28. www.webermfg.ca
ISO 9001 : 2008 Registered
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MATERIAL PROPERTIES
P20 Tool
Material Aluminum Invar NVD Nickel
Steel
lb / in3 0.282 0.098 0.293 0.322
Density
kg / m3 7800 2720 8130 8910
Yield psi 143000 7980 40000 61400
Strength MPa 990 55 276 411
psi 30 x 106 10 x 106 21 x 106 17 x 106
Stiffness
GPa 205 70 145 114
Thermal in / inoF 7.0 x 10-6 12.9 x 10-6 0.7 x 10-6 7.2 x 10-6
Expansion mm / mmoC 12.6 x 10-6 23.6 x 10-6 1.3 x 10-6 13.1 x 10-6
Btuin
Thermal Ft2hroF 201 1452 73 610
Conductivity
W / moC 29 210 11 88
Hardness Brinell 270-480 20-160 120-180 330-380
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29. www.webermfg.ca
ISO 9001 : 2008 Registered
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NVD NICKEL VS ELECTROFORMED SHELL
1. 25mm per 100 hr deposition rate 1. 25mm per 2000 hr deposition rate
2. Uniform thickness & temperature 2. Shell thickness is not uniform
3. Negligible residual stress 3. Inherent residual stresses
4. Cavities made sequentially from the same 4. Cavities made simultaneously from different
mandrel mandrels
5. Little variation from cavity to cavity 5. Problematic variation from cavity to cavity
6. Replace damaged shell in 3 weeks 6. Replace damaged shell in 16-30 weeks
7. Hollow deposition possible in many cases 7. Cannot do hollow
8. 0.999 pure Ni – weldable and no de- 8. Sulfates contamination from electroplating
lamination bath = difficult welding + de-lamination risk
9. No environmental impact (closed system)
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Other Applications
For NVD Nickel Shells
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NICKEL PART www.webermfg.ca
APPLICATIONS
AEROSPACE COMPONENTS
• Weber has produced NVD Nickel Leading Edges for stationary engine vanes
• Outer air surface is created from accurately machined, reusable female metallic master
Examples of Nickel leading edge or
erosion strips
0.25mm (0.010”) thickness
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DESIGN &
MANUFACTURING
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TOOL DESIGN
• Extensive CAD/CAM capabilities
• 10 workstations running:
• UG-NX, IDEAS, Catia
• Innovative designers are working with customers to
contribute to processes and provide tooling solutions.
• Our team manages all information and supports the
machining, assembly and CMM teams.
• Strict revision control on all documents and designs.
• Part of the Weber focus of building relationships and
responding to customer needs.
• CAD data transfer in:
1. STEP, IGES and VDA (BI-DIRECTIONAL)
2. IDEAS NX5 (NATIVE)
3. CATIA V5R20 (NATIVE)
4. UNIGRAPHICS NX6 and NX7.5 (NATIVE )
5. SOLID-EDGE V20 (NATIVE)
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34. www.webermfg.ca
ISO 9001 : 2008 Registered
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PROGRAM MANAGEMENT
• On Time deliveries are paramount at Weber.
• Manufacturing schedules reviews conducted weekly.
• Progress reports are sent to customers bi-weekly.
• In House transportation within North America.
• Global customs expertise - We export and import responsibly.
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35. www.webermfg.ca
ISO 9001 : 2008 Registered
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CERTIFICATIONS
• Quality standard is ISO 9001:2008
• Registered with Canadian Controlled Goods Program - Registration No. 22921
• CWB W47.1, W59 Welding certificates
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36. www.webermfg.ca
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Manufacturing and Mold Making
Departments
• Weber has a large number of Machining, Fabrication and
Assembly bays to suit all the shapes and sizes of your tooling
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37. www.webermfg.ca
ISO 9001 : 2008 Registered
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Equipment Highlights
Five 5-Axis Deckel Maho Machining Centers
• State of the art machining.
• Hypermill 5- Axis software.
• 590 in/min max cutting speed
with 8,000-10,000 RPM.
• Machining aerospace parts
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38. www.webermfg.ca
ISO 9001 : 2008 Registered
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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/PowerMill
Machining Software.
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ASSEMBLY BAY SET UP FOR MULTIPLE MOLD BUILDS
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42. www.webermfg.ca
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Equipment Highlights
• Tryout Presses
• Wemhoner 3250 ton
• Fully rebuilt in 2005/6
• Steam and Oil
Heating capability
• Full vacuum system
for molding Class “A”
SMC panels
• Ott 500 ton
• Steam and Oil
Heating Capability
• Vacuum system
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QUALITY ASSURANCE www.webermfg.ca
• 2 Computer Controlled CMM’s
• Certification of Models, Tooling Aids, Molds,
Steel & Finished Parts to Math Data
• Diffracto Class-A Surface Quality Verification
• Certificate of Conformance
• Detailed Inspection Reports issued to Customer
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IN HOUSE PATTERN SHOP
•REN or epoxy models
•Manufacturing of patterns
for casting of aluminum
face sheet or mandrels
•Aluminum castings can
include cast-in-place
heating/cooling lines if
required
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Customers from around the world
choose Weber to take advantage of:
1. EXPERIENCE - Over 45 years of mold-making experience producing a wide
range of large, class A, custom mold solutions in P20 steel, NVD Nickel, Invar
and Aluminum.
2. INNOVATION – Design knowledge gained from experience in various
competitive markets is continually applied for new engineering developments.
3. CAPACITY & CAPABILITY – Large, fully integrated Mold Design and
Manufacturing Shop can handle large tools, and manage large, multiple tool
programs efficiently, and professionally.
4. NVD NICKEL SHELLS – A unique mold making material, NVD nickel shell
tooling provides an alternative for rapid, accurate, high quality composite
production. Class A surfaces and conformal heating & cooling designs support
shorter cycle times and uniform mold face temperatures.
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