cmp company presentation email print

Confidential Wittmann & Associates, Inc.

Wittmann & Associates, Inc.dba Custom Molded Plastics

155 E. Capitol DriveSuite 6c

Hartland, WI 53029262-367-3702

Fax 262-367-3704


Considerations for process determination• Design criteria including form-fit-function, mating

part consideration

• Capital budget for tooling

• Expected part cost and EAU

• Timing

• Material determination and part environment


Resins

• Determine physical requirements, part environment (UV/Chemicals), industry certifications (UL/NSF), and price targets.

• Popular resins: ABS, HDPE, HMWPE, LDPE, LLDPE, HIPS, PP, PC, PVC, Nylon, PETG, Acrylic

• Alloys: Usually developed for a specific application

• Fillers: Talc, glass, ect

• Color: Dry or liquid

• Additives: UV, fragrance

• Cap sheets for sheet: UV/chemical resistance, gloss requirements, patterns


ROI Analysis

• Process #1 (EAU 1,000)

• Tooling = $5,000

• Pc part = $12

• Diff in tooling = $30,000

• Diff in pc = $6

• Payback = 5,000 pcs or 5 years

• Process #2 (EAU 1,000)

• Tooling = $35,000

• Pc part = $6

• If EAU was 10,000 pc’s, payback is still 5,000 pc’s but the payback is ½ year. Industry standard is payback in 12-18 months


Extrusions

• Tooling is relatively inexpensive

• Pc cost is low, but dependent on volumes (in ft.)

• Can create shapes (profiles) or tubes

• Most common materials : ABS, HIPS, HDPE, PVC

• Ability to co-extrude in order to tie different durometer materials together or colors


Extrusion examples


Applied Plastics – Oak Creek, WI

Extrusions• 130,000 sq ft facility

• 22 extrusion lines

• Maximum tube diameter is 6” and profile extrusion maximum is 12”

• Single, dual, and triple durometer capabilities

• Complete secondary operations including drilling, notching, printing, embossing, heat sealing, solvent bonding, sonic welding, and assembly

Garland Manufacturing Co. -Saco, MaineUHMW Profile extrusions and machining• Ability to extrude

UHMW PE as well as machine lower volumes or as a secondary operation

• Gar-Dur© - minimum molecular weight of 4.2 million

• UHMW is highly abrasion resistant, a low coefficient of friction, and high impact strength


Gar-Dur© - Samples



Thermoforming

• In-line (thin gauge), Cut sheet (heavy gauge)

• Tooling is relatively inexpensive. Ability to create large parts.

• PC part cost is high

• Can create simple shapes to intricate shapes with texture and formed in features. After the part is formed it is trimmed on a CNC to create the perimeter, holes, slots, etc.

• Texture can be in the sheet or mold (pressure form)

• Most common materials: ABS, HIPS, HDPE, PC

• Ability to create features thru numerous secondary operations


Thermoforming examples


General Plastics – Milwaukee, WI

Thermoforming• 51,000 sq ft facility

• Vacuum and pressure forming utilizing both single and rotary equipment with maximum sheet size of 5’x10’ with a 4’ draw

• CNC routers both 3 and 5 axis. Maximum impression is 5’x10’

• Complete assembly as well as secondary operations including painting, silk screening, pad printing, heat bending, and solvent welding


Injection Molding

• Tooling is expensive

• Pc part is low

• Suits parts that are high volume

• Can create features on both sides of the parts

• Ability to create a finished part in one operation

• Texture is in the mold

• Common materials: PP, PE, HIPS, ABS


Injection Molding examples


Tailor Made Products – Elroy, WI

Injection Molding• 100,000 sq ft. facility

with an additional 15,000 sq ft of warehousing

• Sister company is one of the Midwest largest tool shops

• Processing all commodity resins as well as engineering resins

• Machine sizes range from 100 ton to 1880 ton


Structural Foam and Gas Assist• Structural Foam

• Tooling is less than inj.

• Pc part is more

• 3-4 times more rigid than inj.

• Gas Assist

• Tooling more than inj

• Design considerations


Lomont Molding – Mount Pleasant, IA

Structural Foam, Gas –assist, Injection

• 100,000 sq ft facility with an additional 16,000 sq ft. in warehouse

• In house tool build that is fully equipped for initial builds, repair, and maintenance

• 43 molding stations and 20 single platen machines

• 25,000 sq ft, secondary operations that includes 2 paint lines, shielding, silk screening, hot stamping, and assembly


Rotational Molding

• Tooling is inexpensive (fabricated or cast)

• Part cost is high

• Excellent for large parts, structural wall sections (single or double wall)

• Resins is somewhat limited to PE, PVC, Nylon

• Tolerances is a major obstacle


Rotational Examples


Promens – West Chicago, ILRotational Molding

• 125,000 sq ft facility – ISO certified. Multi-national locations

• PRO-E for part and tool design

• Maximum part size is 115” spherical. All machines are computer controlled to maximize part consistency

• CNC trimming, foaming, inserts, spin welding, and assembly


Blow Molding


• Pc part cost is low

• Part can create panels, bottles, tanks, packaging


Blow Molding examples


Quality Custom Molding – Linn, MO

Skandia Plastics – Sheboygan, WI

Blow Molding• Machine capabilities

from 16 oz to a 50lb shot

• Ability to mold all commodity resins as well as engineering grades

• Secondary operations include assembly, packaging, distribution, and decorating


Fiberglass

• Open molding variations: Hand layed up, sprayed up, closed cavity bag molding.

• Tooling is inexpensive

• Pc cost is high

• Closed molding variations: Light RTM, RTM.

• Tooling is inexpensive

• Pc part is high

• Compression Molding: Pressure and heat


• Pc part is low


Fiberglass Examples


Fiber-Tech Franksville, WIFiberglass Molding

• Hand layed-up, vacuum bagging, resin infusion, LRTM, RTM

• In house tool design and fabrication – life time tool guarantee

• 5 axis CNC trimming

• Complete secondary operations including: painting, assembly/sourcing, gaskets, decals, hardware application, etc.

Exothermic Molding – Kenilworth, NJRIM Molding• Rigid and flexible

formulations

• FR formulations to meet UL requirements as needed

• In-house tooling

• Complete in house secondary operations including: painting, assembly (including outside purchased components), packaging, and kitting


RIM Samples



William John InternationalGlobal Sourcing

• Sources from North America, Mexico, Asia, and Europe

• Local warehouse sources to help support inventories

• Plastics, castings, machine parts, fabrications, textiles, electronic components

• Sources have the ability to provide complete products, assemblies, and individual components

Affiliated Products – Mayville, WIWire Harnesses/cable assemblies



TMS Milwaukee, WIMetal Fabrications

• 80,000 sq ft facility, ISO 9001-2000

• MIG, TIG, and spot welding

• Certified to AWS standards

• Ability to cut, shear, laser, bend, weld, stamp, punch, and rivet

• Design support offered utilizing Solid Works


Contacts

Blake Stuckey ([email protected])

Wittmann & Associates, Inc

Dba Custom Molded Plastics

155 E. Capitol Drive

Suite 6c

Hartland, WI 53029

262-367-3702 Fax 262-367-3704

www.custommoldedplastics.com

cmp company presentation email print

Documents

injection molding tooling

pc ability

rotational molding tooling

extrusions tooling

tooling expected

gas assist tooling

inexpensive pc cost

sq ft facility vacuum