lc mold introduction presentation 070815

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



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



Multi-Shot Molds

• Multi-shot scanner parts

• Some parts include over molding a clear lens



Multi-Shot Molds

• Breast pump parts

• Unscrewing molds

• Multiple mechanical slides

• Medical cleanliness requirements



Medical Parts

• Insert molded parts

• Used in automated assembly cell

• Parts for De Vinci Surgical Operation System

• Medical cleanliness requirements



Medical Parts

• Medical centrifuge assembly

• Automotive Fluid Canister



Clear Parts

• Hot runner applications

• Unscrewing molds

• Living hinge parts



Caps & Closure Parts

• Optical sensor

• Interchangeable versions

• Hot runner application

• 3-shot mold

• Rotating center plate



3-Shot Rain Sensor

• Technical insert molded parts

• Battery case includes a pre-mold and overmold



Insert Molded

• Technical insert molded parts

• 2-shot part

• Automated collar insertion application



Throttle By Wire

• Technically demanding parts with multiple slides and lifters pulling on multiple angles



Window Components

• Numerous angled shut-off surfaces



Large Technical Part

• Each small tube includes a splined shut-off

• Orientation of each splined tube is different

• Approximately 16” diameter




• Large automotive air box part

• Mold includes multiple mechanisms moving in all axis




• Pro E

• Pro Manufacturing

• SolidWorks

• AutoCAD

• Mechanical Desktop

• Master Cam

• SmartCAM

• Mold Flow Simulation



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



Design Capabilities

• Manufacturing Feasibility Analysis

• Robust APQP Process

• Cross-function events

• Geared towards identifying potential product defects prior to starting the mold design phase



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”



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



CNC Machining

• Cavity and core are prepared for heat treatment.

• Ejector pin plates, rails and other mold base plates rough machined



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



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



Large CNC Machining

• Huron High Speed Machining Center

• Accuracy to +/-.0001

• Machines heat treated steel with little post machining polishing required



CNC Machining

• Waterlines are gun drilled on a horizontal boring bar machine

• Rotary table makes machining all sides of mold base plates much easier



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



5-Axis Machining

• Roders high speed making centers in environmentally controlled room

• High speed machining of electrodes almost eliminates the need to hand polishing



Electrode Machining

• Makino high speed CNC machining centers used to produce both electrodes and steel mold components

• Flexibility aimed at accommodating shortened lead-times



Component Machining

• CNC turning for round cores

• Great for caps and closure molds

• Accuracy within +/- .0002



CNC Turning

• OD/ID Grinding of round cavities and cores

• Great for caps and closure molds

• Accuracy within +/- .0001



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



CNC Sinker EDM

• Latest CNC EDM machine by Sodick

• Faster cutting times

• Better surface finishes



CNC Sinker EDM

• 3 Sodick Wire EDM Machines

• Submerged burning

• Tapering capabilities

• Hole poppers for installing start holes



CNC Wire EDM

• Staff of highly skilled mold makers

• Perform all finish grinding, fitting, assembly and troubleshooting



Mold Makers

• Highly skilled mold polisher produce surface finishes up to A2 in-house

• Lens and mirror finishes are performed by outside contract services



Mold Polishing

• Mold components are marked with a low level laser engraver

• Steel type, hardness, component number can all be engraved



Laser Engraving

• Inspection of critical steel dimensions

• First piece inspection

• ISO-9000 certification scheduled for mid 2015



Quality Department

• Old world craftsmen

• Precision injection molds

• Engineered to perform

• Program management

• Focused customer service

• Fast delivery schedules



Thank You

lc mold introduction presentation 070815

Documents

edison place

medical parts

clear parts

hinge parts

demanding parts

multishot scanner parts

multishot molds

caps closure parts