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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
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Confidential Wittmann & Associates, Inc.
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
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Confidential Wittmann & Associates, Inc.
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
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Confidential Wittmann & Associates, Inc.
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
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Confidential Wittmann & Associates, Inc.
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
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Confidential Wittmann & Associates, Inc.
Extrusion examples
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Confidential Wittmann & Associates, Inc.
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
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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
Confidential Wittmann & Associates, Inc.
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Gar-Dur© - Samples
Confidential Wittmann & Associates, Inc.
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Confidential Wittmann & Associates, Inc.
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
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Confidential Wittmann & Associates, Inc.
Thermoforming examples
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Confidential Wittmann & Associates, Inc.
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
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Confidential Wittmann & Associates, Inc.
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
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Confidential Wittmann & Associates, Inc.
Injection Molding examples
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Confidential Wittmann & Associates, Inc.
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
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Confidential Wittmann & Associates, Inc.
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
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Confidential Wittmann & Associates, Inc.
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
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Confidential Wittmann & Associates, Inc.
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
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Confidential Wittmann & Associates, Inc.
Rotational Examples
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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
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Confidential Wittmann & Associates, Inc.
Blow Molding
• Tooling is expensive
• Pc part cost is low
• Part can create panels, bottles, tanks, packaging
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Confidential Wittmann & Associates, Inc.
Blow Molding examples
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Confidential Wittmann & Associates, Inc.
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
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Confidential Wittmann & Associates, Inc.
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
• Tooling is expensive
• Pc part is low
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Confidential Wittmann & Associates, Inc.
Fiberglass Examples
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Confidential Wittmann & Associates, Inc.
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.
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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
Confidential Wittmann & Associates, Inc.
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RIM Samples
Confidential Wittmann & Associates, Inc.
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Confidential Wittmann & Associates, Inc.
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
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Affiliated Products – Mayville, WIWire Harnesses/cable assemblies
Confidential Wittmann & Associates, Inc.
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Confidential Wittmann & Associates, Inc.
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
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Confidential Wittmann & Associates, Inc.
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