Total Solutions From Design Through Distribution

Phillips Plastics Corporation®

Phillips Plastics Corporation® is a premier source for the design, manufacture anddistribution of custom plastic and metal injection molded components. Serving originalequipment manufacturers in virtually every market since 1964, the Company is ranked as oneof the top 30 custom injection molders in the United States. With a comprehensive offering ofstate-of-the-art manufacturing technologies – supported by in-house experts in plastic injectionmolding, micro molding, multi-shot molding, medical molding, metal, magnesium, thin wall,windows and precision decorating – Phillips has helped countless customers raise the barfor products that possess the best combination of performance, size and aesthetics.

From automotive components to medical dePhillips is a trusted and knowledgeable soufrom drawing board to packaged product.

vices, cell phones to lawn and garden products,rce for the successful development of concepts

Total Solution ProviderPhillips’ total solution approach includes acomplete resource infrastructure to providecutting-edge solutions for even the toughestmolding challenges. From medical devicesto automotive components, cell phonesand lawn and garden products, Phillipsis a trusted and knowledgeable source forthe successful development of concepts –from drawing board to packaged product.Chosen as a supplier for some of the mostclosely guarded programs on the market,Phillips has systems in place to ensurecustomer visits are carefully monitored,production areas are screened to protectpresses and products are shielded fromview. Because we believe that everycustomer’s product inventory is sensitive,Phillips Plastics operates secure facilitieswith restricted access.

Supply Chain ManagerPhillips Plastics has resources in placeto pursue the best supply chain optionsfor customers in all markets. This valueadded service allows us to be actively in-volved in purchasing, delivery, inventorymanagement, and billing, thus allowingour customers to focus on their areas ofexpertise. Our understanding of supply

chain operations both internally andexternally is an important component ofour total solutions offering. This knowledgeresults in the best outcome for not only thecomponents and services we offer, but thesourcing of activities such as sterilization,machining, and stamping and platingamongst others.

Recognizing that managing the flowof products, services, and informationacross the entire supply chain requiresrobust processes, Phillips has invested inthe most up-to-date electronic data (EDI)transfer capabilities. This allows customersto communicate delivery requirementselectronically, and better manage inventorytransfer, billing, and collection for productat Vendor Managed Inventory (VMI) sites.

Phillips’ supply chain managementservices include:• Design through distribution• Assembly, packaging and sterilization• Sourcing components• End use packaging• Supplier quality engineers• Offsite inventory in Mexico

and Puerto Rico

Appliance, automotive, aviation, computer/business equipment,durable consumer, electronics, industrial, lawn and garden, medical,recreational, and telecommunications.

Markets:

Design DevelopmentPhillips’ Design Development Centers have a solid reputation for creating innovative,manufacturable designs. A key differentiator is our commitment to up-front, technology-focused design services. To assist clients in the development of their ideas, Phillips drawsfrom a formidable talent pool, with years of design, engineering and manufacturing experi-ence in a multitude of technologies. From the design of small overmold parts (from 0.0001cubic inches) with tight tolerances (±0.0005 inches) to larger and more complex designs, such asmedical devices and enclosures, our team of designers and engineers combine their creativeand technical disciplines to develop realistic manufacturing solutions at competitive costs.

How We HelpDesign Development can both enhance product form and function and define how aproduct is differentiated in the market. We believe that collaboration fuels profitability, sowe apply a synergistic approach to product development, teaming with our customersand alliance partners to consider all aspects of the program. This practice ensures thata multi-talented, cross-disciplined team is allied to create the best product solutions,taking into account ergonomics and aesthetics, as well as functionality and manu-facturability. Aided by rapid on-site prototyping services, lead-times are expedited andcosts reduced when this collaborative approach is used for design verification,marketing models, clinical testing and, even, market-entry production.

Design Development can enhance product form and functio

Integrating design, engineering and manufacturing resources at theconcept phase

Design DevelopmentCore Competencies

• Industrial design – from investigationto concept ideation and refinement

• Mechanical design• Mechanical engineering (material

selection, finite element analysis(FEA), Moldflow)

• Rapid prototyping, including foammodels, breadboard models, SLS/SLAparts, urethane castings, prototypeprocess tooling, prototype tooling(aluminum and P-20), molding inspec resin, process development

• CAD tool expertise in the latest, mostcommon 2D and 3D design tools, suchas Vellum, Adobe® Illustrator, Photoshop,Vellum Solids, Form Z, Pro/MOLDESIGN™

• Market entry tooling• Low volume production• Project management that includes a

convenient, primary contact to ensuremanufacturing involvement in all phases

on and define how a product is differentiated in the market.

Plastics ManufacturingPhillips remains an industry leader because we continuously invest in facilities and technologiesto meet your needs for quality, service, value and speed. With an unsurpassed offering ofin-house production processes and services, original equipment manufacturers that choosePhillips capitalize on the manufacturing strength and subsequent product superiority thatcan only come from a supplier willing to commit to innovation.

State-of-the-art facilities and technologies meet demand for quality, service,value and speed

One Stop ShopAs a turnkey supplier, Phillips’ capabilities span the entire product development cycle, resulting in measurabletime and cost savings for our customers. Our focused factory approach to manufacturing starts with dedicatedprogram management, which ensures all aspects of the production process – from design through distribution– are managed to ensure cost and lead time expectations are met without compromise. And with 10 facilitiesdedicated to plastic injection molding, customers are given multiple options for the manufacture of their product.

High Volume Molding• High cavitation, high speed molding

with automated value-added work cells• Full service tool engineering, design and

build, with life-of-program maintenance• Complete value-added operations• EMI/RFI shielding, electroplating,

automated assembly

Cleanroom and Medical Molding• Dedicated turnkey medical device

manufacturing, including molding,secondary operations, manual andautomated assembly, devicepackaging and drug repackaging

• Class 10,000 clean room• Rapid market-entry tooling for clinical

trials, high cavitation and high volumemolding

Low Volume Molding• Flexible tooling designs• Molding complicated part

geometry, including subassemblyand value-added decorating

• Overmolding and insert molding• Class 100,000 clean rooms for molding

and assembly

Multi-Shot Molding• Pioneer in 2-, 3- and 4-shot molding• Full service tool engineering, design,

construction/sourcing andlife-of-program maintenance

• Value-added production, includingpad printing, ultrasonic weldingand automated assembly

• Highly automated parts handlingand packaging

• Proprietary compatibility database of250 materials for bondability, dimensionalstability and environmental performance

Plastics Capabilities

Small Parts Molding• Automatic production of parts, ranging

from .02 grams to 42 grams• High volume, lights out molding and

precision tolerance (± 0.001") parts,with life-of-program maintenance

• Roundmate and modular tooling• RJG process and press monitoring

Micro Molding• Parts ranging in size from 0.0001-0.003

cubic inches• Material options include engineering

grade resins and implantable graderesins, such as PEEK™, and metal alloyssuch as 316, 17-4, 420, and Kovar®

Precision Decorating• Specialized decorative painting• Laser etching/marking on raw resins• Value-added operations• Automatic assembly

Lenses• White room environment to

control airborne contaminantsand minimize rejects

• Transform translucent materialsinto highly visible lens/windowapplications for all markets

• World-class lens decorating,including pad printing, in-molddecorating, in-mold labeling, hardcoating, anti-reflective coating

Insert Molding• Plastic molded around

plastic/metal inserts• Fully automated cells for repeatable

insert loading/placement and part testing• Process control/monitoring for low to

zero PPM defective levels

Plastics Capabilities

Time is Money We built our operations integratingadvanced technology with our skilled workforceto cater to the needs and expectations of today’stime-critical business environment. In Phillips,customers find the optimum resource to helppropel products quickly and competitivelyinto the marketplace.

Metals ManufacturingApplying Phillips’ injection molding expertise to metals was a natural evolution for a companylike ours that is continually seeking new innovations to enhance customer product. Attractedby the potential cost and lead time savings, as well as the design flexibility that both of thesetechnologies offer, Phillips has made substantial investments in state-of-the-art processingequipment to provide the marketplace with a comprehensive source for metal injectionmolding (MIM) and magnesium injection molding (MAG).

Materials• Low-alloy steels• Soft magnetic alloys• Stainless steels• Specialty materials, including Titanium, GHS4, N90 HX, M-2, Kovar®

Enhancing customer product through a logical transfer of Phillips’ expertise

Metal Injection MoldingOur MIM design expertise, combined with extensive experiencemolding a variety of metals, allows us to serve customers in bothexisting and new markets with full production capabilities.

• Design services for consolidating parts and foreliminating secondary operations

• Small complex geometries• Micro molding from 0.0001 to 0.003 cubic inches,

with tolerances as little as ±0.0005 inches• Dimensional tolerances of ±0.5% or better• A complete metallurgy lab

Complimentary design guides for MIM and magnesium injection molding processes are available online atwww.phillipsplastics.com.

Magnesium Injection MoldingPhillips is the only custom injectionmolder of both plastic and magnesium inNorth America. Our machines range from245 tons to 935 tons and we offer value-added secondary operations, such asmachining, painting and assembly.

Magnesium benefits:• Environmentally friendly, light weight,

high density (>98%), near net-shapeintricate metal parts

• Part sizes: 20-200 square inches; shotsizes .1-4 pounds

• Capable of molding thin walls (<0.02 in)• Inherent EMI/RFI shielding capabilities• Superior tool life that is two to five

times greater than conventionalcasting processes

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Origen® CenterThe Origen® Center supports the Company’s need for dedicated training facilities, as wellas new business incubation and overflow production space.

TrainingA full-time staff and permanent trainingfacilities meet the development needsof Phillips’ work force of 1600 people.

New Business IncubationThe Origen® Center incubates and fosterstechnologies that have a high probability ofsuccess but are vulnerable without initialshelter. Administrative support, humanresources, training and maintenance

State-of-the-art facilities and technologies mee

services are provided, reducing theprohibitive costs associated withstand-alone facilities.

Overflow ProductionA flexible manufacturing area serves as aquick response facility for production andsupports new technologies until they haveachieved critical mass in sales or the peopleskills to support the investment of astand-alone facility.

Resource CentersPhillips Plastics Corporation’s commitment to innovation is a primary reason for our dedicatedresource centers, which support automation, research and development, technology incubation,manufacturing and training needs.

Supporting automation, R&D, technology incubation, and training

Technology CenterThe Technology Center has both theexpertise and technology – materials,mechanics, automation, electronics,plastics processing, bioengineering andmetallurgy – to enhance the most complexmanufacturing processes; to examine newproduct and process opportunities; and toevaluate, design and build automation sys-tems. Customers who use the TechnologyCenter’s engineering and technology ex-pertise, gain access to some of the mostadvanced products and processes in themarketplace, as well as to technology thathelps reduce time-to-market, increasethroughput, lower costs andimprove quality.

The Technology Center offers:• New product development, automation

services, program management• Electrical, chemical, and mechanical

engineering; materials science andengineering; coating and finishingengineering; medical devices; ceramics;and electroluminescence/lighting

• Testing and evaluation• FEA, market analysis

et demand for quality, service, value, and speed

LocationsDesign Development• Hudson, Wisconsin• Sunnyvale, California

Manufacturing – Plastics• Eau Claire, Wisconsin• Hudson, Wisconsin• Medford, Wisconsin• Menomonie, Wisconsin• New Richmond, Wisconsin• Phillips, Wisconsin

Manufacturing – Metals• Menomonie, Wisconsin• Eau Claire, Wisconsin (MAG)

Resource Centers• Eau Claire, Wisconsin• Menomonie, Wisconsin• Phillips, Wisconsin• Prescott, Wisconsin

Global ResourcesTo serve global needs, Phillips Plastics maintains strategic alliances with business partners worldwide whoprovide complementary services including tooling, manufacturing, and vendor managed inventory servicesclose to our customers and use points.

Quality System RegistrationAll manufacturing facilities operate under one or more of the following: ISO 9000, ISO 13485,TS 16949, ISO 14001, and FDA standards.

For additional information, contact:Phillips Plastics Corporation™

Opportunity Development877.508.0251info@phillipsplastics.comwww.phillipsplastics.com

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© 2006 Phillips Plastics Corporation®