Soft Touch Textured skins for Automotive Interior utilizing Weber's unique Nickel Vapor Deposition Process.

1. www.webermfg.ca
ISO 9001 : 2008 Registered
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WEBER MANUFACTURING TECHNOLOGIES INC.
Tooling for Automotive Interiors
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2. www.webermfg.ca
ISO 9001 : 2008 Registered
www.webermfg.ca
COMPANY 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 offers high quality tooling in nickel, steel, invar and aluminum,
and precision CNC machined aluminum parts.
Over the last 15 years, Weber has developed 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.
135 employees, 135,000 sq. ft. facility
On-site CAD Design capable (UGS, CATIA)
Certified ISO 9001:2008
Canadian Controlled Goods Program registered
Modern simultaneous 5-Axis CNC machining centers
Full complement of CNC contour mills, gun-drills, vertical mills, and EDM machines
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3. www.webermfg.ca
ISO 9001 : 2008 Registered
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HEAD OFFICE, MOLD MANUFACTURING, AND NICKEL VAPOUR DEPOSTION
PLANT ALL LOCATED AT MIDLAND, ONTARIO, CANADA
PLANTS
OVERVIEW
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4. www.webermfg.ca
ISO 9001 : 2008 Registered
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COMPANY HISTORY
1962 Established Weber Manufacturing (Windsor) Limited
1967 Relocated to a new building in Midland, Ontario
Established the Weber Tool & Mold Division
1989 Established the Nickel Tooling Technology (NTT) Division
1991 Sold our first Nickel Shell
1998 Built and tested NVD Pilot Plant
1999 Designed and Built Large Scale NVD Plant
2000 Commissioned the NVD Nickel Division
2001 Produced our first Nickel Shell in February
2004 Company purchased by American Capital Strategies and TMB Industries
2007 Company purchased by Zynik Capital Corporation
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5. www.webermfg.ca
ISO 9001 : 2008 Registered
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Automotive Exterior Automotive Interior
Key
Market Home & Building
Areas
Aerospace
Key Market Areas
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ISO 9001 : 2008 Registered
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QUALITY CERTIFICATIONS
• ISO 9001:2008 certified
• Boeing Certified Supplier
• Registered with Canadian Controlled Goods Program - Registration No.
22921
• CWB W47.1, W59 Welding certificates
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ISO 9001 : 2008 Registered
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QUALITY ASSURANCE
ISO 9001:2008 Certified
2 Computer Controlled 5-axis CMMs
3 Full Time CMM Operator/Inspectors
Full Certification of Models, Tooling Aids,
Molds & Finished Parts to Math Data
Steel Hardness Check on Incoming
Blocks
Diffracto Class-A Surface Quality
Verification
Detailed Inspection Reports sent to
Customer
Mold Completion Check List
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WEBER MACHINE CAPACITY
Weber has a total of 32 large CNC machines;
• 6 5-Axis CNC Mills • 5 Droop & Rein 3-Axis CNC Mills
• 2 4-Axis CNC Mills • 2 EDM Machines
• 3 Vertical Mills • 3 Various Detail Machines
• 3 Tarus CNC Gun Drills • 2 Vertical Presses
• 4 Horizontal CNC Boring Mills • 2 CMM Measuring Machines
Weber also has various welding and checking tools;
• Yag Laser Welder • Profilometer
• Thermal Spray • Hardness Testing
• Tig & Mig Welder • Ultrasound Thickness Checking
• ARC Welder • Thermal Imaging
• Aluminum Oxide, Glass • Laser Pyrometer
bead and sand blasting.
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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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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 Machining
Software.
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ISO 9001 : 2008 Registered
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AEROSPACE PART MACHINING
Boeing B787 wing components machined in Aluminum
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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
• 4 Production chambers, 1 R&D
• 24 X 7 operation
• 400,000 lbs Ni deposition capacity
• 5.7’ X 9.8’ shell size capacity
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ISO 9001 : 2008 Registered
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NVD – DEPOSITION PROCESS
• Carbon monoxide given off by
the reaction is collected and
reused in a closed loop system.
• Deposition of Nickel from a vapour
creates solid nickel on the outside
surface of a heated mandrel, under
low pressure in a sealed chamber
• The mandrel is a precision, CNC
machined duplication (“master”), of
the desired shape and surface. It is
infinitely re-usable for duplicate nickel
shells
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ISO 9001 : 2008 Registered
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COMPETITIVE PROCESS COMPARISON
Electroformed Nickel Shell NVD Nickel Shell
1. 0.25mm per 20 hr growth rate 1. 0.25mm per 1 hr deposition rate
2. Shell thickness is not uniform during growth 2. Uniform thickness during growth
3. Inherent residual stresses 3. Negligible residual stress
4. Cavities made simultaneously from different 4. Cavities made sequentially from the same
mandrels mandrel
5. Problematic variation - cavity to cavity 5. Little variation from cavity to cavity
6. Replace damaged shell in 12+ weeks 6. Replace damaged shell in 3 weeks
7. Delaminating risk as shells are created in 7. Full shell thickness is deposited in one
multiple grinding and growth steps step with growth being very uniform.
8. Sulfates contamination from electroplating 8. 0.999 pure Ni – weldable and no de-
bath = difficult welding + de-lamination risk lamination
9. No environmental impact (closed system)
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ISO 9001 : 2008 Registered
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NICKEL VAPOUR DEPOSITION
• The re-usable deposition mandrel is placed in the NVD
chamber and heated to approximately 180 C.
• Nickel is deposited onto the mandrel at a rate of 0.010in
(0.25 mm)/hr of thickness regardless of size
• Mandrel must be cleaned and prepared prior to each
deposition
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ISO 9001 : 2008 Registered
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AUTOMOTIVE INTERIOR NICKEL TOOLING
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ISO 9001 : 2008 Registered
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CUSTOMERS – OEM, TIER 1 & TIER 2
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IN HOUSE MASTERING & PATTERN SHOP
In-house Manufacturing of
Wrapped Master Models.
Extensive Master Model
Wrapping Experience with all
Interior Components.
In-house Manufacturing and Seam
Engraving of Hard Epoxy Master
Models.
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RECENT PROGRAMS
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FORD C346 – FORD FOCUS
WEBER MANUFACTURED WRAPPED MASTER
MODEL & THE FINAL EPOXY MASTER MODEL
SLUSH TOOLING – (15) 2-CAVITY TOOL SETS
(6) SINGLE CAVITY TOOLS
(INCLUDING INTEGRATED POWDER SAVERS)
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JC49 – DODGE JOURNEY – LHD & RHD
WEBER MANUFACTURED WRAPPED MASTER
MODEL & THE FINAL EPOXY MASTER MODEL
12 LHD TOOLS– 6 RHD TOOLS
SPRAY TOOLING WITH INTEGRATED
HEATING SYSTEM
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ISO 9001 : 2008 Registered
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CHRYSLER LX (CHRYSLER 300)
BOTH LHD & RHD FULL INTERIORS
IP, FRONT & REAR DOORS, LEFT & RIGHT
CONSOLE PANELS
WEBER MANUFACTURED WRAPPED MASTER
MODEL & THE FINAL EPOXY MASTER MODEL
IP SLUSH TOOLING – 8 LHD IP TOOLS,
2 RHD IP TOOLS
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ISO 9001 : 2008 Registered
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DODGE LD (DODGE CHARGER)
IP, FRONT & REAR DOORS, LEFT & RIGHT
CONSOLE PANELS
WEBER MANUFACTURED WRAPPED MASTER
MODEL & THE FINAL EPOXY MASTER MODEL
SLUSH TOOLING – 8 LHD TOOLS
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BMW F25 – BMW X3 - LHD & RHD
WEBER MANUFACTURED WRAPPED MASTER MODEL
SUBSTRATE & THE FINAL EPOXY MASTER MODELS
SLUSH TOOLING – 16 LHD TOOLS
– 6 RHD TOOLS
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ISO 9001 : 2008 Registered
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HIGH PRESSURE INJECTION MOLDS FOR INTERIORS
Nickel shells are mounted into
steel cavity shoes and fully BMW F07 – (BMW 5 SERIES)
supported for injection tooling.
Rim Overmold
PUR Overmold
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NEGATIVE VAC & IMG NICKEL SHELLS FOR INTERIOR
FULL CONTROL OF HOLE PATTERN &
SPACING
PRECISION PLACEMENT OF VACUUM HOLES
IN THE VEIN DETAIL ONLY TO MINIMIZE
VISIBILITY
.008” VACUUM HOLES EVERY 10mm
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ISO 9001 : 2008 Registered
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ADVANTAGES OF NICKEL VAPOUR DEPOSITION FOR NEGATIVE
VACUUM AND IMG AUTOMOTIVE TOOLING
ELECTROFORM POROUS NICKEL VAPOUR DEPOSITION
NICKEL EXAMPLE POROUS NICKEL EXAMPLE
VACUUM HOLE PLACEMENT ON NVD NICKEL SHELLS IS DONE PRIOR TO SHELL
DEPOSITION WITH FULL CONTROL OVER GRID DENSITY. PLACEMENT OF THE
VACUUM HOLES IS IN THE VEIN DETAIL GIVES SUPERIOR IMG SKIN RESULTS.
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TYPICAL NVD POROUS NICKEL SHELL
VIEW OF SHELL SIDE & FRONT
NVD POROUS NICKEL SHELLS
HAVE THE SAME STRENGTH
AS NVD SHELLS WITHOUT
VACUUM HOLES
VIEW OF SHELL BACKSIDE
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29. NVD TEXTURED NICKEL SHELL PROCESS FLOW INCORPORATING A LEATHER WRAP MASTER MODEL
CNC Machine Leather Wrap Substrate CMM Leather Wrapping of LWM CMM Inspection / Cast Silicone Negative
Model (LWM) Substrate Inspection / Approval Substrate Commission from LWM
CAD Data, Engineering information, and Purchase Order.
Cast Epoxy Master Enhance Epoxy Epoxy Model CMM
Model Model Seam Lines Commission / Inspection
Design model, mandrel and mold.
Build Silicone Cast Silicone Negative
Support Mold from Epoxy Master
Cast Silicone onto Nickel Vapour Shell Stripping and Mold Inspection and
CNC Machine Mandrel Mandrel Deposition Process Mold Assembly Approval
Repeat Steps for Multiple Molds/Shells

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PRECISION LASER WELDING
ON SITE TEXTURE REPAIR SPECIALISTS
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ADVANTAGES OF NICKEL VAPOUR 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
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32. www.webermfg.ca
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ADVANTAGES OF NICKEL VAPOUR 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
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ISO 9001 : 2008 Registered
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DESIGN CAPABILITIES
• Extensive CAD/CAM capabilities
• 8 workstations running:
• UG NX – Primary CAD Software
• IDEAS, Catia, Solid Edge and AutoCAD
- used for translations
• Innovative designers work with customers to
contribute to processes and provide tooling
solutions.
• Our Design Team manages all project
information and supports the Machining,
Moldmaking and CMM teams.
• Strict Engineering Change revision control on
all documents and designs to AS9100 standard
• Full time in-house IT Department for
CAD/CAM/Network support
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CONTACTS
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