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NVH & foam air ductsGaskets, seals, body protection, mouldings & vacuum forming.

World class engineering solutions

From the production of the smallest automotive component to the most complex fully assembled units, Avon Group continues to exceed expectations with their consistently high quality products.

We are one of Europe’s leading manufacturers of moulded door frame insulation produced from a wide range of polyolefin foam.

We provide a full service to manufacturers, taking parts from concept to production. We are one of the only companies in the UK with TS 16949 and ISO 14001 accreditations supplying into automotive NVH Sealing Solutions.

Our sales and engineering teams can offer technical expertise and innovative solutions to suit your requirements. Our expert skills are available to our customers through all stages of product design, development and product introduction. Beyond the manufacture of plastic or foam parts, we provide additional fabrication and completion of fully assembled units. Whether it’s metal, plastic or foam/fabric components, we can offer our customers a complete solution to their requirements.

Best valueWe offer a rapid quotation service and work to satisfy both functional and cost requirements, as well as the most cost effective, consistently high quality products on an on-going basis. Our quality department offers a service to suit your needs, from the simplest sample sign-off, through to full PPAP submissions. We offer new materials and methods of manufacture, as and when they become available.

ClientsOur client portfolio includes major global automotive manufacturers and companies involved in the manufacture of lighting, electronics, packaging, agricultural equipment, vehicles, medical, leisure and sports goods.

NVH & foam air ducts Gaskets, seals, body protection, mouldings & vacuum forming.Avon Group has played a key role in the car manufacturing industry since 1979, offering the flexibility and service that adds best value to any production facility.

Avon Group is a

partner

Foam air ducts

Avon Group innovates in NVH technology, promoting the advantages of Polyethylene foam as an alternative to rigid air ducts

PE foamAvon Group produces PE foam air ducts using a forming process that creates a highly flexible and lightweight alternative to rigid ducting. Our engineering capabilities allow us to thermoform the PE foam into air ducts for diverse application areas within a vehicle. All types of complex shapes and structures can be achieved. We also provide design and testing options to help your product development process.

Where PE foam needs additional properties it is possible to add reinforcement, strengthening and acoustic enhancements to aid fixing.

Advantages of PE include:• Weight reduction of up to 65% • Enhanced thermal insulation ensuring a reduction in energy loss• Elimination of condensation to reduce bacteria build up• Reduction in acoustic noise to reduce squeak and rattle• Elimination of odour to ensure no smell or fogging• Greater flexibility with good restoring behaviour• Simplicity in handling & assembly

Fully formed air duct production

Following months of air flow analysis, the need to reduce vehicle weights and improve acoustic performance whilst eliminating odour, has resulted in one of Avon Group’s most significant investments. A capability that not only meets the expectations of our customers but exceeds them.

Non-phenolic re-con felts

This recycled material is a low cost, easy to use product. It can be supplied adhesive coated, with easy release or

plain. Due to its structure, this material can be kiss cut to help with assembly.

NVH encapsulated foams

Specially developed cut foams, encapsulated in a technical filmic bag, supplied with air extracted and

sealed. Parts are fitted into the BIW and ‘popped’ to allow foam to fit into areas with difficult entry.

Interior trim

A wide range of foam cut parts sealing against noise, vibration and airborne dust.

Fuel tank foams

Specially developed fuel/flame resistant foams, fitted in fuel tanks. Eradicates tank noise.

Wheel protection

To protect alloy wheels against scratches and to protect the brake components from dis-colouring

(through rust).

Extruded window, door seals & cowel strips

Produced in rubber, rubber to metal and TPE. All extrusions can be supplied with adhesive and flock coating. Stops water

ingress and vibration noise around doors & windows.

Anti squeak silent tapes

Durable, abrasion resistant SA backed tapes. Eradicates squeak noise. Can be supplied kiss cut on a reel for easy

dispensing.

Spare wheel holder A robust solution for holding spare wheels firmly in place, avoiding squeaks and rattles.

Rubber to metal & composite bonding

Bushes, engine mounts, suspension components.

ThinsulateA highly technical material used for NVH applications. Parts can be supplied with adhesive coating,

sealed edges or in simple plain pieces.Can be used throughout the vehicle.

Mirror/door insulation

Compression formed Polyethylene mouldings giving acoustic and sealing benefits.

Body protection & interior trim

A range of twin extruded materials, formed to be used throughout the vehicle as protection when

moving around the factory. Proven to have provided major savings in relation to repair costs.

Foam ducting

Lightweight and dramatically improved acoustic benefits, the foam ducting is used in areas such as HVAC.

Water shedders

Vacuum formed components that fit inside the door module, allowing water dispersion through the sills,

whilst giving a high level of acoustic damping. Supplied with a robotically applied bead of Butyl sealant.

Glovebox felts

A range of ultra-thin woven components, used to minimise high frequency noise and rattles, supplied adhesive backed,

with quick release technology.

Tail lamp & head lamp gaskets

Closed cell foams sealing the lamp to the body of the car. This stops water ingression into the vehicle.

Under bonnet NVHMoulded acoustical insulation for vehicle under bonnet and engine compartments. High temperature

resistance is a key feature of these products.

Rubber fully assembled air ducts Clean side air ducts. Air to throttle body allowing for dynamic movement of the air filter. Available in NBR, low swell EPDM

and Vamacs for high temperature.

Reinforced plasticsReinforced PA66 & PPA nylon offers huge advantages over steel & aluminium alloys in both weight saving

and extreme temperature resistance.Can be used throughout the vehicle.

Instrument & facia panel components

Avon Group offers kiss cut instrument panel dial pads and a wide range of 2D anti vibration and sound absorption

materials.

Rigid protectionIf a vehicle needs protecting during manufacture or shipping, Avon Group can provide a solution. Our bespoke, vacuum formed car protection range consists of PE foam laminated to a rigid polyolefin sheet. The parts are vacuum formed and then trimmed to size. This provides a soft foam inner that is in contact with the vehicle and a rigid outer skin that completely protects that area of the vehicle, be it an internal or external area.

The parts fit precisely onto the vehicle and are held in place using a variety of techniques. These parts are reusable. We not only supply vacuum formed protection, but complement this with other products we manufacture, such as die-cut and extruded foam products and tapes.

Advantages of vacuum formingVacuum forming is a very adaptable technology, allowing both flexible and rigid mouldings in a number of materials. Vacuum forming in many applications offers a significantly lower cost alternative to injection moulded and pressed components. This results from lower tooling costs, especially during the development phase of any project where components are likely to require engineering modifications.• Lower equipment costs (in

comparison to injection moulding)• Shorter possible lead-times from

concept through to production• Lower tooling costs compared to

many other plastic manufacturing techniques

• Families of parts can be accommodated cost effectively on one tool

• Less costly design changes, due to lower tooling modification costs

• The ability to manufacture parts with thinner wall sections

• The ability to manufacture flexible foam components easily

• The component profile can be easily modified to accommodate several trim variations

Overall vacuum forming offers a flexibility and diversity of component options, which is further reinforced by low tool costs and allows ongoing engineering modifications.

Non-vehicle usesAs well as vehicle use, our protection products are also suited to transit packaging for fragile components.

Other finishing operations:• 5 axis CNC trimming machines• Purpose-built press tools• Hand routing/trimming• Ultrasonic welding• 6 axis robotic pressure sensitive

adhesive application

FinishingAvon Group can process a wide range of foam and plastics in a variety of colours, grains and thicknesses. Materials can be standard colours or colour matched to suit your application. A wide variety of finishes are possible, from smooth gloss or matt surfaces, up to rough grained textures. Material thicknesses of 0.4mm up to 12mm can be formed.

Vacuum formed protection

Avon Group’s reusable PE foam protection has found a niche in car manufacture, protecting a vehicle’s exterior and interior throughout its build or shipping. Many other industries also benefit from these protective products.

Wheel protection and interior trim

After several years of product development, Avon Group has engineered a solution for wheel protection which protects the rim and brake shoes with a quick release design. Interior trim protection products are also available to help avoid damage to interior trim & upholstery whilst in the production process.

High speed CNC travelling head pressesThese machines are able to produce shapes straight from sheet or rolls. Using this technology, we can maximise material by rotating the heads 360 degrees with multi-cavities and typically produce thousands per hour, dependent on our clients’ particular requirements.

Vacuum formed weather sealWe have the facilities and know-how to deliver high-quality, vacuum formed weather-sealing solutions. Prototyping can be performed rapidly and economically through our tooling partners and in-house skills.

Robotically applied sealing productsTo complement our vacuum forming process, we have invested in a sealant application cell utilising a 6-axis robot. Water shedders and related products have butyl sealants applied. This makes Avon Group a one-stop-shop for weather management solutions.

Oscillating knife cutterThis offers the very latest cutting, without the need for tooling. Using CAD we are able to optimise any shape and/or design requirement for you. This process is innovative, fast and accurate and can be used for a range of materials, from sponge rubbers to fibres and insulations.

Waterjet cuttingWaterjet cutting machines utilise some of the most advanced technology available. An ultra high pressure intensifier pump system pressurises the water before forcing it through a nozzle as small as 1.0mm in diameter. The jet can cut through virtually any material with improved edge quality.

Compression mouldingLow investment, short lead-times and light weight are the signatures of polyethylene compression mouldings. Avon Group produces numerous forms used in NVH, thermal management and trim applications.

Kiss cuttingWe offer high speed kiss cutting and full waste removal in one process.

NVH encapsulated foam solutionsThis is a highly cost effective and innovative solution to body-in-white NVH issues. It was developed by Avon Group and is supplied to numerous OEMs. Cut blocks of urethane foam are placed in a uniquely designed bag and vacuum drawn, then the product is heat sealed. This makes for an operator-friendly product that is easy to position and deploy.

ExtrusionsWe offer effective, bespoke solutions in rubber, rubber to metal, TPE & twin material extruded profiles, vehicle door seals & edge protectors. All profiles come with the added advantage of self-adhesive backing and flock coating where required. Utilising our own die makers, we can offer speedy and economic tooling to meet the demands of our customers.

Other capabilities

Avon Group’s commitment to manufacturing gives you access to a wide range of complementary services.

Avon Group is a

partner

Polyethylene foam compression moulded insulatorsThermo-forming is a manufacturing process for thermoplastic parts. A precise combination of temperature and pressure make the material adapt to the shape of a mould – and obtain the required part. With the thermo-formation process we can produce very diverse parts, including those with variations of thickness, blind and through holes, adhesive zones, plastic dressings or overlays and special surface finishes.

The parts can have the surface stamped with the logos or references of our clients. Thermo-conformed parts are excellent sealing gaskets, preventing water, air and damp from entering. The parts also give added acoustic insulation in areas such as rear view & door mirrors, total door insulation, speaker surrounds and under bonnet applications.

NVH & vibration damping materialsAvon Group manufactures a wide range of noise insulation and vibration damping materials for the automotive, public transport vehicle and construction industries.

The noise insulation range includes monolayer and multi-laminate composites, which are available in sheet, roll or cut shape forms. The vibration damping materials are designed to give substantial noise reduction where structure-borne vibration is a problem. The materials are environmentally safe and completely non-toxic.

A full range of profiles are available upon request.

Thinsulate

Our customers demand a greater depth of service from concept to S.O.P. Our structure includes Technical Sales Engineers to handle concepts and ideas and Project Engineers to manage product introduction. We are mindful of the need for quality, cost and speed from a cross-functional team and our AQP (Advanced Quality Planning) process will analyse the requirement and determine:

• The best equipment• The best process• The best raw material format• Optimum operator requirements• Robust quality procedures• Ideal packaging and handling

specifications• Meeting environmental obligations

From initiation, all projects are managed in a structured and practical manner utilising contemporary project management tools including APQP and Concern and Corrective ActionReporting Documents (CCARs). We also hold scheduled launch readiness reviews where the customer is actively encouraged to participate.

We have initiated a strategy of low-cost sourcing activities which focuses on the products and processes that complement our capabilities in the UK. This allows us to diversify within our field.

We have developed relationships with suppliers of products and services in China, India and eastern Europe, sourcing raw materials including extrusions and foams (block & cut) and finished goods including rubber, PU and plastic injection mouldings.

QualityQuality is fundamental to our success and the success of our clients.

Avon Group holds the following quality and environmental accreditations:• TS 16949• BS EN ISO 9002• BS EN ISO 14001

This makes us one of the only UK-based suppliers in this sector to meet these exacting standards.

Low-cost sourcingLow-cost sourcing is Avon Group’s response to the demand for local supply in the UK to deliver best value.

Complete serviceAvon Group is committed to providing a complete service from prototype to production.

We are the UK’s leading manufacturer of vacuum formed car body protection systems.

Martin JarvisSales DirectorAER Stafford,Cannock, Staffordshire.

We can vac-form a whole range of plastics, as well as Polyethylene foam from 30kg/m3 up to 200kg/m3. Further enhancements can also be made with the addition of foam pads, fitting clips and injection moulded mating parts. This gives the customer the complete solution. The cost benefits of vac forming against more traditional moulding processes are passed on to the customer. Whether, plastic or foam components, we can offer our customers a complete solution to their requirements. Our close relationships with our suppliers across the world enables us to be at the forefront of new materials and processes and helps us retain the competitive advantage.

Avon Group are very proud of our highly experienced staff and of the contribution they give to the success of our world class automotive products.

Processing capabilities

• Aerosol, gaskets & seals

• Die cutting/kiss cutting

• Extrusion & lathe cut washers

• NVH solutions

• Phosphating, rubber to metal & plastic bonding

• Plastic injection moulding (rigid & flexible)

• Rubber 2K & rubber overmoulding

• Technical rubber & polyurethane foam moulding

• Textile shapes & assemblies

• Tool production & technical design

• Vacuum forming (rigid & foam)

• Water cutting

Avon Group Manufacturing Ltd.30 Vale Lane,Bedminster, Bristol BS3 5RUUnited Kingdom

Tel: +44 (0)117 904 3355Fax: +44 (0)117 904 [email protected]

Avon Engineered Rubber Ltd.Maerdy, Ferndale,Mid Glamorgan,South WalesCF43 4FPUnited Kingdom

Tel: +44 (0)1443 735000Fax: +44 (0)1443 [email protected]

P & D Manufacturing Ltd.Unit A11, Fiveways Trading Estate,Westwells Road, Hawthorn,Corsham, WiltshireSN13 9RGUnited Kingdom


PP Injection Moulds & Mouldings Ltd.Lower Bevers Brook Industrial Estate,Redman Road,Calne, WiltshireSN11 9PLUnited Kingdom


AER Stafford Ltd.Bellsize Close, Norton Canes,Cannock, StaffordshireWS11 9TQUnited Kingdom


Avon TSA Ltd.Blaenant Works, Brynmawr, GwentNP23 4BXUnited Kingdom


Avon Engineered Rubber Inc.843 Commerce Parkway,Carpentersville, IL.60110, USA

Tel: 001-224-293-6170Fax: [email protected]

United Polymers s.r.o.Továrni 605,P.O. Box 114753 01 HraniceCzech Republic

Tel: +420 581 699 511Fax: +420 581 699 [email protected]

Every effort has been made to ensure that the information contained in this brochure is accurate as of November 2013. Avon Group reserves the right to introduce at any time modifications, or changes to their products. E&OE.Please recycle. Printed in the UK on paper from sustainable sources. © 2014 Avon Group. All rights reserved.AG-AERS-01-10.13

www.avon-group.co.uk