automotive interiors

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ISO 9001 : 2008 Registered

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WEBER MANUFACTURING TECHNOLOGIES INC.

Tooling for Automotive Interiors

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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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PLANTS OVERVIEW

HEAD OFFICE, MOLD MANUFACTURING, AND NICKEL VAPOUR DEPOSTIONPLANT ALL LOCATED AT MIDLAND, ONTARIO, CANADA

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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

COMPANY HISTORY

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Automotive Exterior Automotive Interior

Home & Building

Key Market Areas

Aerospace

Key Market Areas

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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 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

QUALITY ASSURANCE

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WEBER MACHINE CAPACITY

• 6 5-Axis CNC Mills

• 2 4-Axis CNC Mills

• 3 Vertical Mills

• 3 Tarus CNC Gun Drills

• 4 Horizontal CNC Boring Mills

• 5 Droop & Rein 3-Axis CNC Mills

• 2 EDM Machines

• 3 Various Detail Machines

• 2 Vertical Presses

• 2 CMM Measuring Machines

Weber has a total of 32 large CNC machines;

• Yag Laser Welder

• Thermal Spray

• Tig & Mig Welder

• ARC Welder

• Aluminum Oxide, Glass bead and sand blasting.

Weber also has various welding and checking tools;• Profilometer

• Hardness Testing

• Ultrasound Thickness Checking

• Thermal Imaging

• Laser Pyrometer

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EQUIPMENT HIGHLIGHTS

• State of the art machining.

• Hypermill 5- Axis software.

• 590 in/min max cutting speed with 8,000-10,000 RPM.

• Machining aerospace parts

Five 5-Axis Deckel Maho Machining Centers

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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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AEROSPACE PART MACHINING

Boeing B787 wing components machined in Aluminum

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• 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

NVD NICKEL PRODUCTION FACILITY

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• Deposition of Nickel from a vapourcreates 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

• Carbon monoxide given off by the reaction is collected and reused in a closed loop system.

NVD – DEPOSITION PROCESS

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Electroformed Nickel Shell NVD Nickel Shell

1. 0.25mm per 20 hr growth rate2. Shell thickness is not uniform during growth 3. Inherent residual stresses4. Cavities made simultaneously from different

mandrels5. Problematic variation - cavity to cavity6. Replace damaged shell in 12+ weeks7. Delaminating risk as shells are created in

multiple grinding and growth steps8. Sulfates contamination from electroplating

bath = difficult welding + de-lamination risk

1. 0.25mm per 1 hr deposition rate2. Uniform thickness during growth 3. Negligible residual stress 4. Cavities made sequentially from the same

mandrel5. Little variation from cavity to cavity6. Replace damaged shell in 3 weeks7. Full shell thickness is deposited in one

step with growth being very uniform.8. 0.999 pure Ni – weldable and no de-

lamination9. No environmental impact (closed system)

COMPETITIVE PROCESS COMPARISON

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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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AUTOMOTIVE INTERIOR NICKEL TOOLING

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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


12 LHD TOOLS– 6 RHD TOOLS

SPRAY TOOLING WITH INTEGRATED HEATING SYSTEM

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CHRYSLER LX (CHRYSLER 300)BOTH LHD & RHD FULL INTERIORS

IP, FRONT & REAR DOORS, LEFT & RIGHT CONSOLE PANELS


IP SLUSH TOOLING – 8 LHD IP TOOLS, 2 RHD IP TOOLS

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DODGE LD (DODGE CHARGER)

IP, FRONT & REAR DOORS, LEFT & RIGHT CONSOLE PANELS


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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HIGH PRESSURE INJECTION MOLDS FOR INTERIORS

Nickel shells are mounted into steel cavity shoes and fully supported for injection tooling.

PUR Overmold

Rim Overmold

BMW F07 – (BMW 5 SERIES)

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NEGATIVE VAC & IMG NICKEL SHELLS FOR INTERIOR

.008” VACUUM HOLES EVERY 10mm

FULL CONTROL OF HOLE PATTERN & SPACING

PRECISION PLACEMENT OF VACUUM HOLES IN THE VEIN DETAIL ONLY TO MINIMIZE VISIBILITY

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ADVANTAGES OF NICKEL VAPOUR DEPOSITION FOR NEGATIVE VACUUM AND IMG AUTOMOTIVE TOOLING

ELECTROFORM POROUS NICKEL EXAMPLE

NICKEL VAPOUR DEPOSITION 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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NVD POROUS NICKEL SHELLS HAVE THE SAME STRENGTH AS NVD SHELLS WITHOUT

VACUUM HOLES

TYPICAL NVD POROUS NICKEL SHELL

VIEW OF SHELL SIDE & FRONT

VIEW OF SHELL BACKSIDE

NVD TEXTURED NICKEL SHELL PROCESS FLOW INCORPORATING A LEATHER WRAP MASTER MODELLeather Wrapping of

SubstrateCast Silicone Negative

from LWMCNC Machine Leather Wrap

Model (LWM) Substrate

CNC Machine MandrelCast Silicone onto

MandrelNickel Vapour

Deposition ProcessShell Stripping and

Mold AssemblyMold Inspection and

Approval

Repeat Steps for Multiple Molds/Shells

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Inspection / ApprovalLWM CMM Inspection /

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Enhance Epoxy Model Seam Lines

Cast Epoxy Master Model

Epoxy Model CMM Commission / Inspection

Cast Silicone Negative from Epoxy Master

Build Silicone Support Mold

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PRECISION LASER WELDINGON 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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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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AUTOMOTIVE EXTERIOR TOOLING

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Automotive Exterior - BMW 6 SERIES Cabriolet (RIM Overmold)

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Volkswagen Eos - Deck-lid Inner and Outer SMC Compression Tools

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Compression & RIM Injection Molds for Dodge Viper

Rear Fascia

Hatch outer

Roof outer

AUTOMOTIVE EXTERIOR – DODGE VIPER Class A Compression Molds

Rear Quarter panel

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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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DATA MANAGMENTData can be received in various formats and ways:

•UG NX, IDEAS, Catia, Solid Edge and AutoCAD formats.•Via E-mail, FTP and Odette

All data received is logged into our system.

Once the data is logged into the system it is translated into UG NX and a Data Translation Sheet is created.

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• A MS Project master timeline is created for every program.

•This master timeline drives various other timelines that specific to each of our manufacturing groups.

• Manufacturing reviews are conducted weekly.

• MS Project timeline reports are sent to customers bi-weekly.

PROGRAM MANAGEMENT

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CONTACTS

automotive interiors

Documents

deposition of nickel

nickel shell tooling

axis cnc mills

nvd nickel division

solid nickel

catia certified iso

quality certifications

axis cnc machining centers