lc mold introduction presentation 070815
TRANSCRIPT
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Manufacturer of Injection Molds Engineered to Perform
• 25 Years in business
• 28,000 Square Foot Modern Facility
• Highly Trained Staff of 30+ Employees
• $6MM Annual Sales
• Privately Held – Financially Stable
• Full Service Supplier including Testing, Inspection, Program Management
• Supplying the Medical, Automotive and Electronics Industries
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Company Profile
• 3 Molds
• 3rd mold is a 4-shot mold
• Robotic transfer between 3 molding presses
• Automation transfers molded tooth brushes into bristle insertion and packaging cell
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Multi-Shot Molds
• Multi-shot scanner parts
• Some parts include over molding a clear lens
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Multi-Shot Molds
• Breast pump parts
• Unscrewing molds
• Multiple mechanical slides
• Medical cleanliness requirements
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Medical Parts
• Insert molded parts
• Used in automated assembly cell
• Parts for De Vinci Surgical Operation System
• Medical cleanliness requirements
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Medical Parts
• Medical centrifuge assembly
• Automotive Fluid Canister
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Clear Parts
• Hot runner applications
• Unscrewing molds
• Living hinge parts
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Caps & Closure Parts
• Optical sensor
• Interchangeable versions
• Hot runner application
• 3-shot mold
• Rotating center plate
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
3-Shot Rain Sensor
• Technical insert molded parts
• Battery case includes a pre-mold and overmold
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Insert Molded
• Technical insert molded parts
• 2-shot part
• Automated collar insertion application
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Throttle By Wire
• Technically demanding parts with multiple slides and lifters pulling on multiple angles
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Window Components
• Numerous angled shut-off surfaces
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Large Technical Part
• Each small tube includes a splined shut-off
• Orientation of each splined tube is different
• Approximately 16” diameter
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Large Technical Part
• Large automotive air box part
• Mold includes multiple mechanisms moving in all axis
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Large Technical Part
• Large automotive air box part
• Mold includes multiple mechanisms moving in all axis
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Large Technical Part
• Large automotive air box part
• Mold includes multiple mechanisms moving in all axis
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Large Technical Part
• Pro E
• Pro Manufacturing
• SolidWorks
• AutoCAD
• Mechanical Desktop
• Master Cam
• SmartCAM
• Mold Flow Simulation
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Design Capabilities
• Mold designs done in 3D
• 2D tool drawing available as required
• Mold simulations prior to starting mold design
• Manufacture feasibility analysis
• Product design assistance
• EOAT tooling designs
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Design Capabilities
• Manufacturing Feasibility Analysis
• Robust APQP Process
• Cross-function events
• Geared towards identifying potential product defects prior to starting the mold design phase
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Program Management
Project InformationWhen did we receive the data?When is the customer expecting a preliminary design?When is the final design due?How many shots are expected to run each year?
Manufacturing Feasibility StudyDoes the 3D data need to be cleaned up before we can start?Is the model file drafted?Do we think the part will warp? Has it been confirmed?Does the part model need to be modified for windage?Is the part moldable?Can we offer any design improvement suggestions?Can multiple components in an assembly be combined?Are there any die-lock conditions?Does the 3D data match the 2D drawing dimensions and tolerances?Does the 3D data need to be modified because of unilateral dimensioning?Are the print tolerances realistic and achievable?Are there any concerns with potential knit lines or flow marks?Are there any concerns about maintainability or reliability?Can the part be vented properly?We can we split the part?Where can we eject the part?Does areas of the tool need to be inserted?Does the specified resin create any concerns about steel wear?Has the customer specified the size and type of the runners?Are mechanisms required to demold any undercuts?Are there any requirements for hydraulics?Is the customers press set-up for hydraulic requirements?Will EOAT be used to remove or load the parts or inserts?Is the part insert molded?Are the insert tolerances acceptable for molding requirements?Are thermo pins or special cooling materials needed?Will hot oil heaters be used to heat the mold?Are spare inserts advisable based on the part requirements?Are date code inserts required? Who's?Is a quick mold change system to be used? Who's?Is a quick water manifold system specified? Who's?Has Melt Flipper runner design been specified for this project?
New Project ReviewL.C. Mold
• Weekly Progress Reports
• Project planning system allows for immediate and accurate status reports
• Planning system graphically illustrates actual verses planned project status
• “If you fail to plan, you plan to fail”
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Program Management
• Numerous CNC machining centers used to produce mold components of all types and sizes
• All CNC machines are modern and up to date, many less than 5 years old
• All machines are well maintained and very accurate
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
CNC Machining
• Cavity and core are prepared for heat treatment.
• Ejector pin plates, rails and other mold base plates rough machined
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
CNC Machining
• Following heat treatment cavity and core details are ground square on all six sides
• Mold base plates are finish ground once all machining operations are complete
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Flat Grinding
• Makino V99L high speed CNC machining center used to produce both extremely accurate mold bases and large cavity blocks
• Allows us to produce custom mold bases to world class standards
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Large CNC Machining
• Huron High Speed Machining Center
• Accuracy to +/-.0001
• Machines heat treated steel with little post machining polishing required
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
CNC Machining
• Waterlines are gun drilled on a horizontal boring bar machine
• Rotary table makes machining all sides of mold base plates much easier
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Mold Base Machining
• Roders 5-axis hard milling CNC machine
• Reduces time to produce mold components
• 5-axis capability makes machining some types of details much easier than by other methods
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
5-Axis Machining
• Roders high speed making centers in environmentally controlled room
• High speed machining of electrodes almost eliminates the need to hand polishing
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Electrode Machining
• Makino high speed CNC machining centers used to produce both electrodes and steel mold components
• Flexibility aimed at accommodating shortened lead-times
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Component Machining
• CNC turning for round cores
• Great for caps and closure molds
• Accuracy within +/- .0002
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
CNC Turning
• OD/ID Grinding of round cavities and cores
• Great for caps and closure molds
• Accuracy within +/- .0001
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
OD / ID Grinding
• 6 Charmilles CNC Conventional EDM Machines
• Erowa quick change electrode tooling on all EDM machines
• Most EDM machines have tool changers for unattended machining
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
CNC Sinker EDM
• Latest CNC EDM machine by Sodick
• Faster cutting times
• Better surface finishes
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
CNC Sinker EDM
• 3 Sodick Wire EDM Machines
• Submerged burning
• Tapering capabilities
• Hole poppers for installing start holes
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
CNC Wire EDM
• Staff of highly skilled mold makers
• Perform all finish grinding, fitting, assembly and troubleshooting
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Mold Makers
• Highly skilled mold polisher produce surface finishes up to A2 in-house
• Lens and mirror finishes are performed by outside contract services
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Mold Polishing
• Mold components are marked with a low level laser engraver
• Steel type, hardness, component number can all be engraved
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Laser Engraving
• Inspection of critical steel dimensions
• First piece inspection
• ISO-9000 certification scheduled for mid 2015
3640 Edison Place, Rolling Meadows, IL 60008
www.lcmold.com 847 593-5004
Quality Department