weber-auto-interior-img-presentation-2015
TRANSCRIPT
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MANUFACTURING & NVD PLANT
WEBER FACILITIES ARE ALL LOCATED IN MIDLAND, ONTARIO, CANADA
• HEAD OFFICES & ENGINEERING
• MOLD MANUFACTURING & ASSEMBLY
• 5-AXIS MACHINING
• NICKEL VAPOR DEPOSITION PLANT
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WEBER CREATES THE LEATHER WRAPPED MASTER MODELS OUR NVD NICKEL SHELL TOOLING WILL REPLICATE
• IN-HOUSE MASTER MODEL WRAPPING EXPERIENCE WITH ALL INTERIOR PARTS
• HIGH ACCURACY 5-AXIS MACHINING & MANUFACTURING OF MASTER MODEL
SUBSTRATES
• EXTENSIVE KNOWLEDGE OF MASTER MODEL APPROVAL REQUIREMENTS WITH OEM’S & TIER 1 SUPPLIERS IN BOTH NORTH AMERICA & EUROPE
MASTER MODEL WRAPPING AND SUBSTRATE MANUFACTURING
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• IN-HOUSE EPOXY MODEL CASTING TECHNOLOGY & EXPERTISE
• 5-AXIS MACHINING OF AIR BAG LOGO LETTERING, RAISED OR POCKET STYLES
• HAND TEXTURING TO HIDE WRAP SEAMS
• 5-AXIS SCRIBING - EDGE OF PART LINES, TRIM LINES, OPENINGS, & PART OR CAVITY IDENTIFICATION AS REQUIRED
WEBER CREATES THE FINAL EPOXY MASTER MODELS OUR NICKEL SHELL TOOLING WILL REPLICATE
FINAL EPOXY MASTER MODEL CASTING AND WRAP SEAM ENHANCING
NVD NICKEL SHELL PROCESS FLOW INCORPORATING A LEATHER WRAP MASTER MODEL
Leather Wrapping of
Substrate
Cast Silicone Negative
from LWM
CNC Machine Leather Wrap
Model (LWM) Substrate
CNC Machine Mandrel Cast Silicone onto
Mandrel
Nickel Vapour
Deposition Process
Shell Stripping and
Mold Assembly Mold Inspection and
Approval
Repeat Steps for Multiple Molds/Shells
CA
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Substrate CMM
Inspection / Approval
LWM CMM Inspection /
Commission
Enhance Epoxy
Model Seam Lines
Cast Epoxy Master
Model
Epoxy Model CMM
Commission / Inspection
Cast Silicone Negative
from Epoxy Master
Build Silicone
Support Mold
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• STATE-OF-THE-ART NICKEL CARBONYL PLANT COMMISSIONED IN 2000
• NO ENVIROMENTAL IMPACT (CLOSED LOOP SYSTEM RECYCLES GASES)
• MAXIMUM DEPOSITION SIZES = 66” x 183” or 90” x 120”
• 400,000 LBS/YR NICKEL DEPOSITION CAPACITY
• 4 PRODUCTION & 1 R&D CHAMBER
• 24 x 7 OPERATION
NICKEL VAPOR DEPOSITION FACILITY
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Nickel Powder Solid Nickel Shape
Chemical Vapour Deposition
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Ni
nickel powder + 4CO
carbon monoxide
Ni(CO)4
nickel carbonyl
Ni(CO)4
nickel carbonyl + Ni
solid nickel
4CO
carbon monoxide
Chemistry
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• RE-USABLE DEPOSITION MANDREL IS PLACED INTO THE DEPOSITION CHAMBER AND HEATED TO APPROXIMATELY 350°F (175°C)
• MULTIPLE NICKEL SHELLS ARE MADE SEQUENTIALLY FROM THE SAME DEPOSITION MANDREL • DEPOSITION MANDREL IS CLEANED, RE-ASSEMBLED, & RE-PREPARED PRIOR TO EACH USE
RELEASED CO GASSES ARE RECYCLED
NICKEL VAPOR DEPOSITION PROCESS
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THE NICKEL CARBONYL GAS FLOWS OVER A RE-USABLE DEPOSITION MANDREL CREATING A UNIFORM THICKNESS NICKEL SHELL AT A GROWTH RATE OF .010”
(0.25mm) PER HOUR REGARDLESS OF THE PART SIZE
SEALED DEPOSITION
CHAMBER
NICKEL VAPOR DEPOSITION PROCESS
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HOT AIR SLUSH MOLDS (All FORCED AIR METHODS, TUBE BUNDLES,
INFRA RED, SAND, ETC.)
PU SPRAY MOLDS
TEXTURED RIM OVERMOLDS HIGH POLISH PU OVERMOLDS NEGATIVE VAC FORM
IMG MOLDS
OIL HEATED SLUSH MOLDS (OIL LINES ON SHELL BACKSIDE)
NVD NICKEL SHELL TOOL APPLICATIONS
ADVANTAGES OF THE NVD PROCESS…
• UNSURPASSED REPRODUCTION OF ANY GRAIN OR SURFACE TEXTURE WITH MOLECULAR LEVEL DEPOSITION
• NO BATHMASTER WITH A CONDUCTIVE COATING REQUIRED
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ADVANTAGES OF THE NVD PROCESS…
• 20x FASTER GROWTH COMPLETED ALL IN ONE STEP
• MUCH MORE UNIFORM SHELL GROWTH
• NO GROWTH LAYERS - 0% CHANCE OF NICKEL SHELL DELAMINATION
• NO RESIDUAL STRESS – NO SHELL DISTORTION
NICKEL VAPOR DEPOSITION CROSS SECTIONS
ELECTROFORMED SHELL CROSS SECTION
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CREATES A NICKEL SHELL, OF SUPERIOR QUALITY, 20 TIMES FASTER THEN THE
ELECTROFORMING PROCESS!
PROVIDES A 5-6 WEEK TIMING ADVANTAGE TO THE 1st TOOL
ADVANTAGES OF THE NVD PROCESS…
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CONSECUTIVE NVD TOOLS TYPICALLY DELIVERED IN 2-3 WEEK INTERVALS
AFTER TOOL #1
EMERGENCY REPLACEMENT OR NEW CAPACITY TOOLS ARE TYPICALLY
DELIVERED 3-4 WEEKS FROM KICK-OFF
ADVANTAGES OF THE NVD PROCESS…
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ADVANTAGES OF THE NVD PROCESS…
• NICKEL SHELLS - 99.98% PURE NICKEL CONTENT
• CLEAN, CONSISTENT, AND VISUALLY MATCHING WELDING & GRAIN REPAIRS
• WEBER REPAIR TECHNICIANS ARE BOTH LASER WELDING & GRAIN REPAIR SPECIALISTS
• REPAIRS CAN BE PERFORMED IN CUSTOMERS PLANTS WORLD WIDE, OR IN-HOUSE AT WEBER
AUTO INTERIOR PROGRAMS
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LATEST VEHICLE INTERIORS WITH TEXTURED SURFACES FROM NVD NICKEL SHELL TOOLING…
FRONT & REAR DOOR UPPERS - SLUSH SKIN PROCESS
2016 MERCEDES GLE COUPE/SUV
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2015 DODGE CHALLENGER
INSTRUMENT PANEL - SLUSH SKIN PROCESS
DOOR PANEL UPPERS – NEGATIVE VAC FORM / IMGL PROCESS
LATEST VEHICLE INTERIORS WITH TEXTURED SURFACES FROM NVD NICKEL SHELL TOOLING…
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2015 FORD MUSTANG
DOOR PANEL UPPERS – NEGATIVE VAC FORM / IMGL PROCESS
LATEST VEHICLE INTERIORS WITH TEXTURED SURFACES FROM NVD NICKEL SHELL TOOLING…
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CURRENT TOYOTA AVALON
INSTRUMENT PANEL – SLUSH SKIN PROCESS
LATEST VEHICLE INTERIORS WITH TEXTURED SURFACES FROM NVD NICKEL SHELL TOOLING…
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CURRENT BMW X3 SUV
INSTRUMENT PANEL - SLUSH SKIN PROCESS
LATEST VEHICLE INTERIORS WITH TEXTURED SURFACES FROM NVD NICKEL SHELL TOOLING…
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CURRENT MERCEDES ML & GL SUV’S
FRONT & REAR DOOR UPPERS - SLUSH SKIN PROCESS
LATEST VEHICLE INTERIORS WITH TEXTURED SURFACES FROM NVD NICKEL SHELL TOOLING…
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2015 FORD F-150 TRUCK FRONT & REAR DOOR PANEL UPPERS
NEGATIVE VAC FORM / IMGL PROCESS
LATEST VEHICLE INTERIORS WITH TEXTURED SURFACES FROM NVD NICKEL SHELL TOOLING…
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CHRYSLER 300 – CURRENT MODEL
Instrument Panels - LHD & RHD Front & Rear Door Panel Uppers
Console Side Panels Process – Slush Cast Skin
DODGE JOURNEY – CURRENT MODEL
Instrument Panel Process – Spray PU Skin
NISSAN ALTIMA – CURRENT MODEL
Instrument Panel – A-Pad and B-Pad Process – Slush Cast Skin
FORD FOCUS – CURRENT MODEL
Instrument Panel Process – Slush Cast Skin
FORD EXPLORER – CURRENT MODEL
Instrument Panel Process – Slush Cast Skin
DODGE CHARGER – CURRENT MODEL
Instrument Panel Front & Rear Door Panel Uppers
Console Side Panels Process – Slush Cast Skin
LATEST VEHICLE INTERIORS WITH TEXTURED SURFACES FROM NVD NICKEL SHELL TOOLING…
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NEW INTERIOR TOOLING PROJECTS UNDERWAY GOING INTO 2015…
FORD EXPLORER DOORS RE-FRESH Process – Slush Cast Skin
GM / OPEL D2JO (ASTRA FOR EUROPE) I.P. Topper Panel Process – Slush Cast Skin
GM ACADIA I.P. TOPPER PANEL Process - IMG Negative Vac-Form Skin
DTNA 38N I.P. TOPPER PANEL Process – Spray PU Skin
BMW X5 - PREVIOUS MODEL
Instrument Panel Process – Slush Cast Skin
PEUGEOT 508 – CURRENT MODEL
Instrument Panel Process – Spray PU Skin
FORD EDGE - CURRENT MODEL
Instrument Panel Process – Slush Cast Skin
LATEST VEHICLE INTERIORS WITH TEXTURED SURFACES FROM NVD NICKEL SHELL TOOLING…
NVD NICKEL SHELL TOOLING BENEFITS FOR THE IMG/L PROCESS
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NVD NICKEL SHELL TOOLING BENEFITS FOR THE IMG/L PROCESS
THE SAME 5-6 WEEK TIMING ADVANTAGE TO THE 1ST IMG/L NICKEL SHELL COMPLETION DUE TO THE MUCH FASTER NVD DEPOSITION RATE
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NVD NICKEL SHELL TOOLING BENEFITS FOR THE IMG/L PROCESS
ELECTROFORM SHELL VACUUM HOLE EXAMPLE
NVD SHELL & LASER DRILLING EXAMPLE
• CONSISTANT 0.18mm (.007”) VACUUM HOLES
• PROGRAMED LASER DRILLING = REPEATABILITY
• MULTIPLE CAVITIES PROCESS IDENTICALLY
• EXCELLENT VACUUM PULL & PERFORMANCE
• IDEAL VACUUM = OPTIMUM GRAIN REPLICATION
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A STRONG, SOLID NICKEL SHELL HAS ONLY THE VACUUM HOLES PASSING THROUGH THE SHELLS THICKNESS
NVD IMG/L NICKEL SHELL EXAMPLE
SIDE CROSS-SECTION
SHELL BACKSIDE
NVD NICKEL SHELL TOOLING BENEFITS FOR THE IMG/L PROCESS
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• SOLID, UN-DESTORTED NICKEL SHELLS ALLOW ACCURATE MACHINING FOR MODULAR STYLE MOUNTING & VACUUM BOX SEALING DESIGN OPTIONS
• NICKEL SHELLS CAN BE EASILY & QUICKLY REMOVED & RE-MOUNTED REPEATABLY TO THE VACUUM BOX ASSEMBLY
NVD NICKEL SHELL TOOLING BENEFITS FOR THE IMG/L PROCESS
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ELECTROFORMED POROUS NICKEL SHELL EXAMPLE
BACKSIDE
NVD NICKEL SHELL TOOLING BENEFITS FOR THE IMG/L PROCESS
SIDE CROSS-SECTION
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• COMPETITIVELY PRICED
• SUPERIOR GRAIN RESOLUTION STARTING POINT
NICKEL SHELL & VACUUM BOX ASSEMBLIES ARE VACUUM BAGGED & VACUUM PULL VERIFIED PRIOR TO SHIPMENT
NVD NICKEL SHELL TOOLING BENEFITS FOR THE IMG/L PROCESS
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NVD IMGL PROCESS NICKEL SHELL & VACUUM BOX ASSEMBLY FOR A 4-CAVITY DOOR UPPER
DELIVERED 16 WEEKS AFTER KICK-OFF!
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NVD IMG PROCESS NICKEL SHELLS & VACUUM BOX ASSEMBLIES FOR 2-CAVITY I.P. TOPPER PANELS
DELIVERED 18 WEEKS AFTER KICK-OFF!
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Weber Supplied IMG/L Negative Vacuum Form Tooling & Assists
• WEBER OBTAINS IMG PART ORIENTATION & RUN-OFF CAD DATA • WEBER DESIGNS AND CONSTRUCTS THE WRAPPED MODEL SUBSTRATE,
WRAPPING OF MASTER MODELS AND ALL APPROVALS • CONSTRUCTION AND CASTING OF THE FINAL HARD EPOXY MASTER
MOTHER MODELS • SEAM ENHANCING, SCRIBING WORK, AND THE FINAL APPROVAL OF
EPOXY MASTER MOTHER MODELS • CREATION OF THE NVD IMG/L NICKEL SHELLS AND REQUIRED
MACHINING WORK FOR MOUNTING ON THE VACUUM BOX ASSEMBLY • INSTALLATION, SET-UP & TESTING OF IMG/L NICKEL SHELL BACKSIDE
WATER HEATING SYSTEM • MANUFACTURE CAVITY VACUUM BOX ASSEMBLY, NICKEL SHELL
INSTALLATION, AND VACUUM PERFORMANCE VERIFICATION
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Contact Information
Robert Sheppard, P. Eng Vice President 705-527-2976 (Office) 705-527-2123 (Cell) [email protected]
Weber Head Office
16566 Hwy. 12
P.O. Box 399
Midland, Ontario
Canada, L4R-4L1
Alan Gobien Business Manager – Automotive Interiors 705-527-2950 (Office) 705-427-3600 (Cell) [email protected]
Weber Head Office
16566 Hwy. 12
P.O. Box 399
Midland, Ontario
Canada, L4R-4L1
Thomas Helle European Sales Agent +49 (0) 7021 978558 (Office) +49 (0) 171 637 7550 (Cell) [email protected]
Greg Leidig U.S. Sales Agent 419-481-3645 (Cell) [email protected]
Stuckerinweg 12
D-73230 Kirchheim/Teck
Germany
2136 Woodmere Court
Toledo, Ohio
43615
U.S.A.