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Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Hethel Engineering Centre
Chapman Way, Hethel
Norwich, Norfolk UK
NR14 8FB
t: +44 (0) 1953 859133
e: info@atprecision.co.uk
atprecision.co.uk
A DIVISION OF
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Active Technologies Over-Moulding (ATO-M)
Equipment, Materials Challenges, Solutions & Case Studies
Active Precision Over mould Market Target Exposure
Connectors PCBA Potting
Engine Components Heat shrink LED Lighting Cable Processing
ATO-M
O-M Fault Analysis Support
O-M Product Design
O-M Product Manufacture
O-M Material
Sales
After Sales / Service &
Repair
Tooling & Equipment
Sales
ATO-M Customer Supporting Objectives
ATO-M
O-M Fault Analysis Support
O-M Product Design
O-M Product Manufacture
O-M Material
Sales
After Sales / Service &
Repair
Tooling & Equipment
Sales
Key Objectives – Tooling and Equipment Sales
• Tooling & Equipment Sales • Offered a range of ATO-M
Precision over-mould machines • Technical Support for customer
obsolescence replacement product(s)
• Product custom tooling solutions, including RP Over-moulded solutions
• Prototype Tooling through to Production Volume solutions
• New Materials for tooling • New technology developments
for equipment • Training Programs / Open Days
Key Objectives – O-M Fault Analysis Support
ATO-M
O-M Fault Analysis Support
O-M Product Design
O-M Product Manufacture
O-M Material
Sales
After Sales / Service &
Repair
Tooling & Equipment
Sales
• O-M Fault Analysis Support
• Customer support of field failure analysis of component parts and or materials.
• Partnered with Henkel • Tooling analysis • Mould Flow (Design
Analysis) • FEA (Design Analysis) • Environmental Testing of
customer designs
Key Objectives – O-M Product Design
• O-M Product Design • Engineering Design support for
application integration • Custom design services • FEA Analysis • Mould-Flow Analysis • 3D Cad Modelling • 2D Drawing • Liase with customer suppliers
for design optimisation and manufacture
• APQP / PPAP – FAIR / ISIR reporting first off part prototypes or production tooling
• Marketing Literature (Instructions / Manual)
ATO-M
O-M Fault Analysis Support
O-M Product Design
O-M Product Manufacture
O-M Material
Sales
After Sales / Service &
Repair
Tooling & Equipment
Sales
Key Objectives – O-M Product Manufacture
ATO-M
O-M Fault Analysis Support
O-M Product Design
O-M Product Manufacture
O-M Material
Sales
After Sales / Service &
Repair
Tooling & Equipment
Sales
• O-M Product Manufacture • Custom Manufacturing Facilities
at Hethel using ISO9001 Standards
• Manufacturing Engineering support for application integration to customer production environment
• Takt Time Analysis Reporting – Labour Cost Analysis (6 Sigma)
• Cell Layout Proposals • PPAP – FAIR / ISIR reporting first
off production process • Control Plan Documentation • Process Documentation • Quality Inspection Process to
ISO9001 Standards
Key Objectives – O-M Material Sales
ATO-M
O-M Fault Analysis Support
O-M Product Design
O-M Product Manufacture
O-M Material
Sales
After Sales / Service &
Repair
Tooling & Equipment
Sales
• O-M Materials Sales • Henkel material sales
• Macromelt ® • Macroplast ®
• Introduction of NEW PA technologies from Henkel
Key Objectives – After Sales / Service & Repair
ATO-M
O-M Fault Analysis Support
O-M Product Design
O-M Product Manufacture
O-M Material
Sales
After Sales / Service &
Repair
Tooling & Equipment
Sales
• After Sales / Service & Repair • Optional service contracts /
maintenance agreements, replacement tooling or inserts.
• Follow up with customers • Breakdown emergency contract
agreements
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Over mould Equipment
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Low Pressure Overmoulding Equipment
Active Precision, a Division of Active Technologies and experts in product design,
manufacturing, material selection, machine design & production with Nordson,
a global supplier of adhesive application systems has partnered to offer a complete
solutions for low pressure over moulding system design.
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
• Field-proven, all-electric technology delivers outstanding durability and value.
• These melt units are ideal for all-electric dispensing via a mould tool or manual/handgun operations.
• Choose from tank capacities of 4, 10, 16, 25, 50 and 100 litres.
• Economize using fixed-speed AC drive and gear pumps with low and high output rates.
• Simplify daily operation using intuitive graphic operator interface, system status at-a-glance and continuously updated temperature monitoring.
• Reduce wear and tear on equipment with low-pressure operation.
• Select 2-, 4-, or 6-gun operation and expand as your production needs change.
• Enhance performance of hot melt adhesives. Leading Zone Concept prevents any control zone temperature from exceeding the leading zone temperature, causing all zones to reach set point temperature simultaneously.
• Reduce adhesive spilling and waste with large, accessible tank opening.
• Access all components quickly and easily using large, removable side panels.
• Connect to a personal computer via RS 232 port for melt diagnostics, setup and programming.
Processing Solutions - Low Pressure Injection Moulding (LPIM)
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
14
Description Low Pressure Over-moulding equipment Manual Load, Automatic mould rotary based low pressure mould system Other design variants available on request Control System PLC
Cycle Time Product/Shot size specific, 10-40s typical
Volume >1M components / year
Locations used Mexico, China and Slovenia
Processing Solutions - LPIM Indexing Table Example
Typical product
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Material Challenges?
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Low Pressure Overmoulding Materials
Active Precision, a Division of Active Technologies and experts in product design,
manufacturing, material selection, machine design & production with Henkel, the global
leader in adhesive technologies has partnered to offer a complete solution for low
pressure over moulding / encapsulation.
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
• The challenge is encapsulating and over-moulding electronics without causing failure or destruction
• Hard, crystalline polymers do not adhere easily to other substrates
• Crystalline polymers require high shear (high pressure) destroying electronic components and damages cables
• Some soft elastomers can over-mould delicate components however heat dissipation issues can cause in-service failures later
• Consider adhesion/cohesion model
Polymer Facts & Trends - The Challenge
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
• Hot Melt Polyamide Adhesive (HMPA‘S) resins protect electronic components • Design can be formed (moulded) in to 3D prescribed shape to optimize space available
within an assembly
• Provides aesthetically pleasing solution
• Ability to over mould cabled products, whilst also creating strain relief protection
• Recyclable compared to epoxy and PU.
• Good adhesion/bonding to other polymers
• Creating sealing of components (water tight encapsulation) IP67 Levels
• Low pressure moulding material can be used as a solution to encapsulate printed circuit board assemblies (PCBA’s), provides additional protection to electronic components
Polymer Facts & Trends - Protecting Electronics
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Comparison of Hot Melt Polyamide Adhesive (HMPA‘S) to common materials used to protect electronic components
Parameter 3D
Shape detail
Pack Space
Cable Exit /
Strain Relief
Shock RDSW /Elec.
IP rated protect
PCB/elec.
Cure time
WIP Adhesion
& cohesion
End of Life
Recycle
HMPA YES LOW YES HIGH HIGH 5 SEC LOW MEDIUM YES
2 X PART PU POTTING NO MEDIUM NO HIGH HIGH HRS HIGH HIGH NO
2 X PART EPOXY POTTING NO MEDIUM NO MEDIUM HIGH HRS HIGH HIGH NO
INJECTION MOULDED POLYMER (CLIPPED/WELDED)
YES MEDIUM YES MEDIUM LOW 3 SEC LOW MEDIUM NO
CONFORMAL COATING NO LOW NO LOW HIGH MINS MED HIGH NO
Polymer Facts & Trends -Comparison Matrix
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Protecting Electronic Components with new thermoplastics & Elastomers
Changes Purpose Consequences
Thermosets to Thermoplastics replacing 2 x part potting compounds
with thermoplastic hot melts
Use of HMPA increases, unit volume declines due to cost and need for less
material
Amorphous to Crystalline polymers harder, stiffer polymers replacing metals should make incorporating sensors and
electronics more practical
Moderate to High temperature materials complex polymers replacing metals and
rubbers 2 x shot moulding provides protection
and manufacturability
Approx. 25% increase in volume of Plastics
driver for polymer research & development
could enable UK to take lead in complex automated manufacturing
Protecting Electronics
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
• Thermal recovery and destruction of HMPA’s in domestic incineration plants, free from any toxins or hazardous compounds
• Reduced part volume of HMPA’s reduce recovery process
• Most new high performance polymers and elastomers can be recovered mechanically, re-ground and recycled
• Many new elastomers can be recycled infinitely
End of Life Cycle Recovery & Recycling Management
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Solutions
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Injection Moulding
Casting
Macromelt ® Moulding p
ress
ure
cycle time
What is Macromelt Moulding?
Macromelt® Moulding = Low Pressure, Adhesive, Injection Moulding A process innovation positioned between casting and injection moulding technologies
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
• High performance polyamide hotmelts
• Solvent free, no safety labels
• 60-80% of raw materials are based on renewables (vegetable oils)
• Long shelf life (2+ years)
• Via colored master batches you can achieve almost every color you need
Macromelt Technology Background
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
• Low Pressure
– Injection pressure between 2 and 40 bar
– No damage of electronic parts
– Moulds can be made of aluminum (low costs)
• Adhesive
– To manufacture parts (connector, PCBs, etc.) which are water tight
– To obtain strain relief on cables
– Products based on natural raw materials – environmentally compatible
• Injection Moulding
– Cycle times typically between 10 and 50 seconds
– Allows higher out than with casting applications
– Clean and simple to use process
Technical Features
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Benefits
• Cost Savings
– Moulds can be made of aluminum instead of steel
– Less adhesive needed compared to traditional casting
– Saves energy by eliminating the heat curing process
• Time Savings
– Fast cycle times (10 to 50 seconds); no extra time for curing
– Simple and clean process with low machine maintenance needs
• Production Space Savings
– No space needed for case storage and curing
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Properties Macromelt
OM 652/657 Macromelt
OM 633/638 Macromelt
OM 673/678
Color amber/black amber/black amber/black
Service temperature range in °C -40 to +100 -40 to +130 -40 to +140
Cold flexibility in °C -45 -30 -40
Application temperature range in °C +180 to +230 +200 to +240 +210 to +240
Shore hardness A 77 A 90 A 90
Adhesion properties e.g. on PA +++ ++ +
Elongation at break in % 400 400 400
Remarks UL94-V0 UL94-V0 UL94-V0
Three standard products on polyamide basis
– For different service temperature ranges
– Each available in amber and in black color • Other grades are available and dependent on your application
Standard Product Ranges
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Order information for direct Active Technology customers
Active Technologies Ref Color Packaging Active Technologies Order
Ref
Macromelt OM 652 Amber 20 kg bag ATO-M Melt 652
Macromelt OM 657 Black 20 kg bag ATO-M Melt 657
Macromelt OM 633 Amber 20 kg bag ATO-M Melt 633
Macromelt OM 638 Black 20 kg bag ATO-M Melt 638
Macromelt OM 673 Amber 20 kg bag ATO-M Melt 673
Macromelt OM 678 Black 20 kg bag ATO-M Melt 678
Macroplast CR6127 white-light-beige 35 kg Drum ATO-M Pott CR6127
Macroplast CR6127 SB15 black 35 kg Drum ATO-M Pott CR6127 SB15
Standard Product Ranges – Order Information
2.0 Kg Samples are available from Active Technologies, please request a quote.
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Properties Macromelt
OM 653 Macromelt
6208/6208 S Macromelt
OM 641/646 Macromelt
OM 648
Color amber amber/black amber/black black
Service temperature range in °C -40 to +100 -40 to +100 -40 to +130 -40 to +130
Cold flexibility in °C -50 -40 -35 -30
Application temperature range in °C +180 to +230 +180 to +230 +200 to +240 +200 to +240
Shore hardness A 77 A 82 A 92 A 93
Adhesion properties e.g. on PA +++ +++ Properties +
Elongation at break in % 400 600/450 650 550
Remarks - UL94-V0 UL94-V0 -
Four innovative products on polyamide basis
New Innovative Product Ranges
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Product Name Color Packaging Active Technologies
Ref
Macromelt OM 653 amber 20 kg bag ATO-M Melt 653
Macromelt 6208 amber 20 kg bag ATO-M Melt 6208
Macromelt 6208 S black 20 kg bag ATO-M Melt 6208S
Macromelt OM 641 amber 20 kg bag ATO-M Melt 641
Macromelt OM 646 black 20 kg bag ATO-M Melt 646
Macromelt OM 648 black 20 kg bag ATO-M Melt 648
New Innovative Product Ranges – Order Information
Order information for direct Active Technology customers
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Case Studies
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Product Case Studies - Product Examples
• ATO-M customer applications have been developed using a range of over-moulded product solutions / techniques.
Encapsulation Encapsulation / Strain Relief PCB Protection / Strain Relief
PCB Protection / Strain Relief PCB Protection / Adhesion PCB Protection / Adhesion Encapsulation
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Product Case Studies
Existing Product Examples
• Over moulded case studies
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Product Case Studies - Existing Product Examples
• Over moulded case studies
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Automated Custom Integration System Custom Manufacturing Solutions Full System Integration Solution High Volume Parts Med / High Cost Tooling High Complexity Part
Automated Machine Single or Dual Slide Design (Linear)
Multi Cavity (Rotary) Integrate Systems (i.e. EOLT, AOI)
Med / High Volume Parts Med / High Cost Tooling
Med / High Complexity Part
Hand Operated Semi Automated Machine Single or Dual Slide Design (Linear) 2-8 Cavity (Rotary) Low / Med Volume Parts Low / Med Cost Tooling Low / Med Complexity Part
A Hand Held Machine
Low Volume Parts Low Cost Tooling
Low Complexity Part Simple Solutions
Production Volumes
Time to Supply Equipment Cost
ATO-M Range L200 / R300
ATO-M Range M100 / M102
ATO-M Range AL1000 / AR2000
ATO-M Range C
<50
- 2
50
≈25
0 –
10
0K
≈10
0K
-
Mill
ion
(s)
<£3K* ≈2-4wks
<£30K* ≈6-8wks
<£77K* ≈10-14wks
*Cost & Time estimated & subject to change and complexity of product design
constraints Quotations available upon request
Product Guide
Cu
sto
me
r
Spe
cifi
c
Customer Specific
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
Confidential & Proprietary This Presentation remains the property of Active Technologies and shall not be reproduced or communicated without written permission
If you have any further requirements please contact Active Precision
Hethel Engineering Centre
Chapman Way, Hethel
Norwich, Norfolk UK
NR14 8FB
t: +44 (0) 1953 859133
e: info@atprecision.co.uk
atprecision.co.uk
Mr Paul K Edwards Over Mould Business Development Manager
(t) 07720 593511 p.edwards@active-technologies.co.uk
Mr Michael Pickles Senior Sales Manager
(t) 07850 208796 m.pickles@active-technologies.co.uk
Active Technologies Contacts