SlideShare a Scribd company logo
www.webermfg.ca
1
www.webermfg.ca
www.webermfg.ca
2
www.webermfg.ca
PLANTS
OVERVIEW
 HEAD OFFICE
 MOLD MANUFACTURING
 5-AXIS MACHINING
 NICKEL VAPOR DEPOSITION PLANT
ALL FACILITIES ARE LOCATED IN
MIDLAND, ONTARIO, CANADA
www.webermfg.ca
3
www.webermfg.ca
STATE-OF-THE-ART NICKEL CARBONYL PLANT
COMMISSIONED IN 2000
4 PRODUCTION AND 1 R&D CHAMBER
24 X 7 OPERATION
400,000 LBS/YR NICKEL DEPOSITION
CAPACITY
5.7’ X 15.3’ NICKEL SHELL SIZE CAPACITY
NICKEL VAPOR DEPOSITION FACILITY
www.webermfg.ca
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www.webermfg.ca
NICKEL VAPOR DEPOSITION
• A RE-USABLE DEPOSITION MANDREL IS PLACED IN THE
DEPOSITION CHAMBER AND HEATED TO APPROXIMATELY
350°F.
• MANDREL MUST BE CLEANED AND PREPARED PRIOR TO
EACH DEPOSITION.
RELEASED CO GASSES ARE RECYCLED
www.webermfg.ca
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www.webermfg.ca
THE NICKEL CARBONYL GAS FLOWS OVER A REUSABLE DEPOSITION
MANDREL CREATING A UNIFORM THICKNESS NICKEL SHELL AT A
GROWTH RATE OF .010” PER HOUR REGARDLESS OF THE PART SIZE
SEALED
DEPOSITION
CHAMBER
www.webermfg.ca
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www.webermfg.ca
ELECTROFORMING NICKEL VAPOR DEPOSITION
1. 0.25mm per 20 hour growth rate
2. Shell thickness is not uniform during growth
3. Inherent residual stresses during growth
4. Cavities made simultaneously from different
bath masters.
5. Problematic variation - cavity to cavity
6. Replace damaged shell in 10+ weeks
7. Delaminating risk as shells are created in
multiple grinding and growth steps
8. Sulfates contamination from electroplating
bath = difficult welding + de-lamination risk
9. Process waste is an environmental concern
1. 0.25mm per 1 hour deposition rate
2. Uniform thickness during growth
3. Negligible residual stress during growth
4. Cavities made sequentially from the same
re-usable deposition mandrel
5. Little variation from cavity to cavity
6. Replace damaged shell in 3 weeks
7. Full shell thickness is deposited in one
step with growth being very uniform.
8. 0.999 pure Ni – weldable and no de-
lamination risks
9. No environmental impact (closed system)
COMPETITIVE PROCESS COMPARISON
www.webermfg.ca
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www.webermfg.ca
TYPICAL APPLICATIONS FOR OUR NVD NICKEL SHELLS
HOT AIR SLUSH MOLDS
(TUBE BUNDLE OR FORCED AIR METHODS) PU SPRAY MOLDS
TEXTURED RIM OVERMOLDSHIGH POLISH PU
OVERMOLDS
NEGATIVE VAC FORM
IMG MOLDS
OIL HEATED SLUSH MOLDS
(OIL LINES ON SHELL BACKSIDE)
www.webermfg.ca
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www.webermfg.ca
WEBER PATTERN MAKERS CREATE THE LEATHER WRAPPED MASTER
MODELS THAT WILL BE REPLICATED BY THE NVD NICKEL MOLDS
EXTENSIVE IN-HOUSE MANUFACTURING
AND WRAPPING EXPERTISE FOR ANY
INTERIOR PART SHAPE.
EXTENSIVE MASTER MODEL APPROVAL
PROCESS EXPERIENCE WITH OEM’S AND
TIER 1 SUPPLIERS.
www.webermfg.ca
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www.webermfg.ca
EPOXY CASTING, WRAP SEAM TEXTURE
ENHANCING, AND CNC ENGRAVING OF
FINAL EPOXY MASTER MODELS ARE
DONE AT WEBER
WEBER PATTERN MAKERS CREATE THE FINAL EPOXY MASTER
MODELS THAT WILL BE REPLICATED BY THE NVD NICKEL MOLDS
NVD NICKEL SHELL PROCESS FLOW INCORPORATING A LEATHER WRAP MASTER MODEL
Leather Wrapping of
Substrate
Cast Silicone Negative
from LWM
CNC Machine Leather Wrap
Model (LWM) Substrate
CNC Machine Mandrel
Cast Silicone onto
Mandrel
Nickel Vapour
Deposition Process
Shell Stripping and
Mold Assembly
Mold Inspection and
Approval
Repeat Steps for Multiple Molds/Shells
CADData,Engineeringinformation,andPurchaseOrder.
Designmodel,mandrelandmold. Substrate CMM
Inspection / Approval
LWM CMM Inspection /
Commission
Enhance Epoxy
Model Seam Lines
Cast Epoxy Master
Model
Epoxy Model CMM
Commission / Inspection
Cast Silicone Negative
from Epoxy Master
Build Silicone
Support Mold
www.webermfg.ca
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www.webermfg.ca
WHAT ARE THE ADVANTAGES OF NICKEL VAPOR
DEPOSITION OVER THE ELECTROFORMING PROCESS??
UNSURPASSED REPRODUCTION OF ANY
GRAIN OR SURFACE TEXTURE WITH
ATOM BY ATOM DEPOSITION
NO CONDUCTIVE LAYER NECCESSARY
www.webermfg.ca
12
www.webermfg.ca
ADVANTAGES OF NICKEL VAPOR DEPOSITION…
20x FASTER GROWTH WITH A MORE
UNIFORM NICKEL SHELL THICKNESS
NVD NICKEL SHELL CROSS SECTION
ELECTROFORMED SHELL CROSS SECTION
NO RESIDUAL STRESS FROM NVD MEANS
NO SHELL DISTORTION
www.webermfg.ca
13
www.webermfg.ca
ADVANTAGES OF NICKEL VAPOR DEPOSITION…
THE NVD PROCESS
HAS A NICKEL SHELL
DEPOSITION RATE
APPROXIMATELY 20
TIMES FASTER THEN
ELECTROFORMING
THE NVD PROCESS TYPICALLY
PROVIDES A 5-6 WEEK TIMING
IMPROVEMENT TO THE FIRST
MOLD COMPLETION
www.webermfg.ca
14
www.webermfg.ca
ADVANTAGES OF NICKEL VAPOR DEPOSITION…
CONSECUTIVE NVD MOLDS
CAN BE DELIVERED IN 2-3
WEEK INTERVALS AFTER
THE FIRST MOLD
EMERGENCY REPLACEMENT
OR CAPACITY NVD MOLDS
CAN BE DELIVERED IN 3-4
WEEKS FROM A KICK-OFF
www.webermfg.ca
15
www.webermfg.ca
PRECISION LASER WELDING
TEXTURE REPAIR SPECIALISTS - ON-SITE OR AT CUSTOMER PLANT
www.webermfg.ca
16
www.webermfg.ca
Current Mercedes M-Class
Doors – Front & Rear
Current Chrysler 300
Instrument Panels, LHD & RHD
Doors, Front and Rear & Console Panels
Current Ford Focus
Instrument Panels
Current BMW X3
Instrument Panels – LHD & RHD
Current Dodge Journey
Instrument Panels
RECENT AUTO INTERIOR PROGRAMS DONE
WITH WEBER AND NVD NICKEL SHELL TOOLING
Current Nissan Altima
Instrument Panel Driver & Passenger Top Pads
www.webermfg.ca
17
www.webermfg.ca
Current Dodge Charger
Instrument Panels
Doors, Front and Rear & Console Panels
BMW X5
Instrument Panels – LHD & RHD
Current Ford Edge
Instrument Panels
Current Peugeot 508
Instrument Panels
Current Ford Explorer
Instrument Panels
RECENT AUTO INTERIOR PROGRAMS DONE
WITH WEBER AND NVD NICKEL SHELL TOOLING
NEW INTERIOR WORK AT WEBER!
 DAIMLER MLC DOORS – CAST SKIN
 DODGE CHALLENGER IP – CAST SKIN
 DODGE CHALLENGER DOORS – IMGL
 DODGE CHARGER IP – CAST SKIN
 FORD EXPLORER DOORS – CAST SKIN
 FORD EXPLORER IP – SPRAY PU
 FORD F150 DOORS - IMGL
 FORD MUSTANG DOORS – IMGL
 TOYOTA AVALON IP – CAST SKIN
 DAIMLER TRUCK IP TOPPER – SPRAY PU
 OPEL D2JO IP TOPPER – CAST SKIN
www.webermfg.ca
18
www.webermfg.ca
IMG/L - Negative Vacuum Forming & Laminating
NVD Technology Benefits
www.webermfg.ca
19
www.webermfg.ca
NICKEL VAPOR DEPOSITION FOR NEGATIVE VAC-FORMING
SIGNIFICANT TIMING ADVANTAGE:
5-6 WEEK IMPROVEMENT DUE TO
THE FAST NVD DEPOSITION RATE
www.webermfg.ca
20
www.webermfg.ca
NICKEL VAPOR DEPOSITION
POROUS NICKEL EXAMPLE
THE 0.18mm (.007”)VACUUM HOLES ARE CREATED DURING NICKEL SHELL
DEPOSITION OR AFTER BY LASER DRILLING. FULL CONTROL OF VACUUM HOLE
DENSITY FOR MAXIMUM VACUUM AND OPTIMUM GRAIN REPLICATION.
NICKEL VAPOR DEPOSITION FOR NEGATIVE VAC-FORMING
ELECTROFORM POROUS
NICKEL EXAMPLE
www.webermfg.ca
21
www.webermfg.ca
ELECTROFORMED POROUS NICKEL SHELL
VIEW OF SHELL BACKSIDE
VIEW OF SHELL SIDE & FRONT
www.webermfg.ca
22
www.webermfg.ca
A VERY STRONG, SOLID NICKEL SHELL
WITH ONLY THE VACUUM HOLES PASSING
THROUGH THE SHELLS THICKNESS
NVD POROUS NICKEL SHELL
VIEW OF IMG SHELL SIDE & FRONT
VIEW OF SHELL BACKSIDE
www.webermfg.ca
23
www.webermfg.ca
NVD POROUS NICKEL SHELLS
 5-6 WEEK TIMING ADVANTAGE
 CONTROLLED VACUUM HOLE PLACEMENT
 SUPERIOR GRAIN REPLICATION QUALITY
 INHERENTLY STRONGER NICKEL SHELL
 COMPETITIVELY PRICED
 MASTERED & MANUFACTURED COMPLETELY IN
NORTH AMERICA
CAVITY IMG SHELL & VACUUM BOX
ASSEMBLY VALIDATION BY VACUUM
BAGGING AND VACUUM PULL TESTING
PRIOR TO CAVITY SHIPMENT FROM WEBER
www.webermfg.ca
24
www.webermfg.ca
www.webermfg.ca
25
www.webermfg.ca
CONTACT INFORMATION
Robert Sheppard, P. Eng
Vice President
705-527-2976 (Office)
705-527-2123 (Cell)
rob.sheppard@webermfg.ca
Weber Head Office
16566 Hwy. 12
P.O. Box 399
Midland, Ontario
Canada, L4R-4L1
Alan Gobien
Business Manager – Automotive Interiors
705-527-2950 (Office)
705-427-3600 (Cell)
alan.gobien@webermfg.ca
Weber Head Office
16566 Hwy. 12
P.O. Box 399
Midland, Ontario
Canada, L4R-4L1
Thomas Helle
European Sales Agent
+49 (0) 7021 978558 (Office)
+49 (0) 7021 978557 (Cell)
thomas.helle@webermfg.ca
Greg Leidig
U.S. Sales Agent
419-481-3645 (Cell)
greg.leidig@webermfg.ca
Stuckerinweg 12
D-73230 Kirchheim/Teck
Germany
2136 Woodmere Court
Toledo, Ohio
43615

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IMG/IMGL Vacuum Form Tooling

  • 2. www.webermfg.ca 2 www.webermfg.ca PLANTS OVERVIEW  HEAD OFFICE  MOLD MANUFACTURING  5-AXIS MACHINING  NICKEL VAPOR DEPOSITION PLANT ALL FACILITIES ARE LOCATED IN MIDLAND, ONTARIO, CANADA
  • 3. www.webermfg.ca 3 www.webermfg.ca STATE-OF-THE-ART NICKEL CARBONYL PLANT COMMISSIONED IN 2000 4 PRODUCTION AND 1 R&D CHAMBER 24 X 7 OPERATION 400,000 LBS/YR NICKEL DEPOSITION CAPACITY 5.7’ X 15.3’ NICKEL SHELL SIZE CAPACITY NICKEL VAPOR DEPOSITION FACILITY
  • 4. www.webermfg.ca 4 www.webermfg.ca NICKEL VAPOR DEPOSITION • A RE-USABLE DEPOSITION MANDREL IS PLACED IN THE DEPOSITION CHAMBER AND HEATED TO APPROXIMATELY 350°F. • MANDREL MUST BE CLEANED AND PREPARED PRIOR TO EACH DEPOSITION. RELEASED CO GASSES ARE RECYCLED
  • 5. www.webermfg.ca 5 www.webermfg.ca THE NICKEL CARBONYL GAS FLOWS OVER A REUSABLE DEPOSITION MANDREL CREATING A UNIFORM THICKNESS NICKEL SHELL AT A GROWTH RATE OF .010” PER HOUR REGARDLESS OF THE PART SIZE SEALED DEPOSITION CHAMBER
  • 6. www.webermfg.ca 6 www.webermfg.ca ELECTROFORMING NICKEL VAPOR DEPOSITION 1. 0.25mm per 20 hour growth rate 2. Shell thickness is not uniform during growth 3. Inherent residual stresses during growth 4. Cavities made simultaneously from different bath masters. 5. Problematic variation - cavity to cavity 6. Replace damaged shell in 10+ weeks 7. Delaminating risk as shells are created in multiple grinding and growth steps 8. Sulfates contamination from electroplating bath = difficult welding + de-lamination risk 9. Process waste is an environmental concern 1. 0.25mm per 1 hour deposition rate 2. Uniform thickness during growth 3. Negligible residual stress during growth 4. Cavities made sequentially from the same re-usable deposition mandrel 5. Little variation from cavity to cavity 6. Replace damaged shell in 3 weeks 7. Full shell thickness is deposited in one step with growth being very uniform. 8. 0.999 pure Ni – weldable and no de- lamination risks 9. No environmental impact (closed system) COMPETITIVE PROCESS COMPARISON
  • 7. www.webermfg.ca 7 www.webermfg.ca TYPICAL APPLICATIONS FOR OUR NVD NICKEL SHELLS HOT AIR SLUSH MOLDS (TUBE BUNDLE OR FORCED AIR METHODS) PU SPRAY MOLDS TEXTURED RIM OVERMOLDSHIGH POLISH PU OVERMOLDS NEGATIVE VAC FORM IMG MOLDS OIL HEATED SLUSH MOLDS (OIL LINES ON SHELL BACKSIDE)
  • 8. www.webermfg.ca 8 www.webermfg.ca WEBER PATTERN MAKERS CREATE THE LEATHER WRAPPED MASTER MODELS THAT WILL BE REPLICATED BY THE NVD NICKEL MOLDS EXTENSIVE IN-HOUSE MANUFACTURING AND WRAPPING EXPERTISE FOR ANY INTERIOR PART SHAPE. EXTENSIVE MASTER MODEL APPROVAL PROCESS EXPERIENCE WITH OEM’S AND TIER 1 SUPPLIERS.
  • 9. www.webermfg.ca 9 www.webermfg.ca EPOXY CASTING, WRAP SEAM TEXTURE ENHANCING, AND CNC ENGRAVING OF FINAL EPOXY MASTER MODELS ARE DONE AT WEBER WEBER PATTERN MAKERS CREATE THE FINAL EPOXY MASTER MODELS THAT WILL BE REPLICATED BY THE NVD NICKEL MOLDS
  • 10. NVD NICKEL SHELL PROCESS FLOW INCORPORATING A LEATHER WRAP MASTER MODEL Leather Wrapping of Substrate Cast Silicone Negative from LWM CNC Machine Leather Wrap Model (LWM) Substrate CNC Machine Mandrel Cast Silicone onto Mandrel Nickel Vapour Deposition Process Shell Stripping and Mold Assembly Mold Inspection and Approval Repeat Steps for Multiple Molds/Shells CADData,Engineeringinformation,andPurchaseOrder. Designmodel,mandrelandmold. Substrate CMM Inspection / Approval LWM CMM Inspection / Commission Enhance Epoxy Model Seam Lines Cast Epoxy Master Model Epoxy Model CMM Commission / Inspection Cast Silicone Negative from Epoxy Master Build Silicone Support Mold
  • 11. www.webermfg.ca 11 www.webermfg.ca WHAT ARE THE ADVANTAGES OF NICKEL VAPOR DEPOSITION OVER THE ELECTROFORMING PROCESS?? UNSURPASSED REPRODUCTION OF ANY GRAIN OR SURFACE TEXTURE WITH ATOM BY ATOM DEPOSITION NO CONDUCTIVE LAYER NECCESSARY
  • 12. www.webermfg.ca 12 www.webermfg.ca ADVANTAGES OF NICKEL VAPOR DEPOSITION… 20x FASTER GROWTH WITH A MORE UNIFORM NICKEL SHELL THICKNESS NVD NICKEL SHELL CROSS SECTION ELECTROFORMED SHELL CROSS SECTION NO RESIDUAL STRESS FROM NVD MEANS NO SHELL DISTORTION
  • 13. www.webermfg.ca 13 www.webermfg.ca ADVANTAGES OF NICKEL VAPOR DEPOSITION… THE NVD PROCESS HAS A NICKEL SHELL DEPOSITION RATE APPROXIMATELY 20 TIMES FASTER THEN ELECTROFORMING THE NVD PROCESS TYPICALLY PROVIDES A 5-6 WEEK TIMING IMPROVEMENT TO THE FIRST MOLD COMPLETION
  • 14. www.webermfg.ca 14 www.webermfg.ca ADVANTAGES OF NICKEL VAPOR DEPOSITION… CONSECUTIVE NVD MOLDS CAN BE DELIVERED IN 2-3 WEEK INTERVALS AFTER THE FIRST MOLD EMERGENCY REPLACEMENT OR CAPACITY NVD MOLDS CAN BE DELIVERED IN 3-4 WEEKS FROM A KICK-OFF
  • 15. www.webermfg.ca 15 www.webermfg.ca PRECISION LASER WELDING TEXTURE REPAIR SPECIALISTS - ON-SITE OR AT CUSTOMER PLANT
  • 16. www.webermfg.ca 16 www.webermfg.ca Current Mercedes M-Class Doors – Front & Rear Current Chrysler 300 Instrument Panels, LHD & RHD Doors, Front and Rear & Console Panels Current Ford Focus Instrument Panels Current BMW X3 Instrument Panels – LHD & RHD Current Dodge Journey Instrument Panels RECENT AUTO INTERIOR PROGRAMS DONE WITH WEBER AND NVD NICKEL SHELL TOOLING Current Nissan Altima Instrument Panel Driver & Passenger Top Pads
  • 17. www.webermfg.ca 17 www.webermfg.ca Current Dodge Charger Instrument Panels Doors, Front and Rear & Console Panels BMW X5 Instrument Panels – LHD & RHD Current Ford Edge Instrument Panels Current Peugeot 508 Instrument Panels Current Ford Explorer Instrument Panels RECENT AUTO INTERIOR PROGRAMS DONE WITH WEBER AND NVD NICKEL SHELL TOOLING NEW INTERIOR WORK AT WEBER!  DAIMLER MLC DOORS – CAST SKIN  DODGE CHALLENGER IP – CAST SKIN  DODGE CHALLENGER DOORS – IMGL  DODGE CHARGER IP – CAST SKIN  FORD EXPLORER DOORS – CAST SKIN  FORD EXPLORER IP – SPRAY PU  FORD F150 DOORS - IMGL  FORD MUSTANG DOORS – IMGL  TOYOTA AVALON IP – CAST SKIN  DAIMLER TRUCK IP TOPPER – SPRAY PU  OPEL D2JO IP TOPPER – CAST SKIN
  • 18. www.webermfg.ca 18 www.webermfg.ca IMG/L - Negative Vacuum Forming & Laminating NVD Technology Benefits
  • 19. www.webermfg.ca 19 www.webermfg.ca NICKEL VAPOR DEPOSITION FOR NEGATIVE VAC-FORMING SIGNIFICANT TIMING ADVANTAGE: 5-6 WEEK IMPROVEMENT DUE TO THE FAST NVD DEPOSITION RATE
  • 20. www.webermfg.ca 20 www.webermfg.ca NICKEL VAPOR DEPOSITION POROUS NICKEL EXAMPLE THE 0.18mm (.007”)VACUUM HOLES ARE CREATED DURING NICKEL SHELL DEPOSITION OR AFTER BY LASER DRILLING. FULL CONTROL OF VACUUM HOLE DENSITY FOR MAXIMUM VACUUM AND OPTIMUM GRAIN REPLICATION. NICKEL VAPOR DEPOSITION FOR NEGATIVE VAC-FORMING ELECTROFORM POROUS NICKEL EXAMPLE
  • 21. www.webermfg.ca 21 www.webermfg.ca ELECTROFORMED POROUS NICKEL SHELL VIEW OF SHELL BACKSIDE VIEW OF SHELL SIDE & FRONT
  • 22. www.webermfg.ca 22 www.webermfg.ca A VERY STRONG, SOLID NICKEL SHELL WITH ONLY THE VACUUM HOLES PASSING THROUGH THE SHELLS THICKNESS NVD POROUS NICKEL SHELL VIEW OF IMG SHELL SIDE & FRONT VIEW OF SHELL BACKSIDE
  • 23. www.webermfg.ca 23 www.webermfg.ca NVD POROUS NICKEL SHELLS  5-6 WEEK TIMING ADVANTAGE  CONTROLLED VACUUM HOLE PLACEMENT  SUPERIOR GRAIN REPLICATION QUALITY  INHERENTLY STRONGER NICKEL SHELL  COMPETITIVELY PRICED  MASTERED & MANUFACTURED COMPLETELY IN NORTH AMERICA CAVITY IMG SHELL & VACUUM BOX ASSEMBLY VALIDATION BY VACUUM BAGGING AND VACUUM PULL TESTING PRIOR TO CAVITY SHIPMENT FROM WEBER
  • 25. www.webermfg.ca 25 www.webermfg.ca CONTACT INFORMATION Robert Sheppard, P. Eng Vice President 705-527-2976 (Office) 705-527-2123 (Cell) rob.sheppard@webermfg.ca Weber Head Office 16566 Hwy. 12 P.O. Box 399 Midland, Ontario Canada, L4R-4L1 Alan Gobien Business Manager – Automotive Interiors 705-527-2950 (Office) 705-427-3600 (Cell) alan.gobien@webermfg.ca Weber Head Office 16566 Hwy. 12 P.O. Box 399 Midland, Ontario Canada, L4R-4L1 Thomas Helle European Sales Agent +49 (0) 7021 978558 (Office) +49 (0) 7021 978557 (Cell) thomas.helle@webermfg.ca Greg Leidig U.S. Sales Agent 419-481-3645 (Cell) greg.leidig@webermfg.ca Stuckerinweg 12 D-73230 Kirchheim/Teck Germany 2136 Woodmere Court Toledo, Ohio 43615