Faspro Technologies - General 9.2013

GENERAL CORPORATE PRESENTATION

IF YOU CAN IMAGINE IT

WE CAN MAKE IT!


ABOUT US

• Founded in 1995• First capability was in design and photo chemical milling

of thin gauge metals for EMI/RF board level shields

• In house capabilities expanded to include electroplating, laser cutting, forming and assembly since then.


ABOUT US

• Headquartered in Arlington Heights, IL - a NW Suburb of Chicago

• Second Facility in Elk Grove Village, IL• Third Facility in Arlington Heights, IL added 7/2013• Proud to be “Made in America” serving an

international market!• Photo Chemical and Electroplating Processes are

ISO 9001:2008 certified.• ITAR Registered


TARGETED INDUSTRIES

• Wireless/Mobile Core Technology– Board and System Level EMI/RF Shielding– Wireless Antennas– Battery Contacts– Clips

• Wireless/Mobile Devices– Smartphones– Cellular Phones– 2-Way Radios– Bluetooth Ear Pieces and Headsets– Bluetooth Speakers, Printers, Etc.


TARGETED INDUSTRIES

• Consumer Electronics– Game Consoles– Game Controllers– Blu-Ray/DVD Players– Digital Music Players– Digital Cameras– Fitness Monitoring Devices– Small Appliance Electronics


TARGETED INDUSTRIES

• Computers/Servers– Board Level Shields– Brackets and Bezels– Contacts and Clips


TARGETED INDUSTRIES

• Telecom Infrastructure– Base Station Apparatus Components– Board and System Level Shielding– Brackets, Bezels– Cell Site Apparatus Components– Antenna Components


TARGETED INDUSTRIES

• Aerospace/Defense/DOD– Custom Wearable Battery Packs– Communications and Surveillance– Replacement Parts


TARGETED INDUSTRIES

• Medical Devices– Patient Monitoring, Diagnostics, Drug Delivery


TARGETED INDUSTRIES

• Industrial/Building– Elevator Components and Sub-Assemblies– Safety Devices

– Window H/W


TARGETED COMPONENTS

• Antennas

• Board Level Shields

• Battery Contacts

• Fabricated Springs


OUR UNIVERSE

• If the device or system has electronics in it, then there is a 90% probability that Faspro Technologies has made, is making or can make the thin gauge metal components to shield, clip or make electrical contacts happen!


OUR UNIVERSE

• Prototyping Thin Gauge Metals– 24 Hr. Quote Turnaround– Parts completed in as little as 24 Hrs.– Tooling design/build in-house

• Short-run Manufacturing– Project Dependent– Typical volumes under 100,000 annual units– Tooling design/build sub-contracted– Components & Assy. Completed in-house

• Small Electro-Mechanical Assembly Work


OUR UNIVERSE

• Punch Presses (focus on small parts)– Blank, Pierce, Bend, Form, Draw, Trim– Six OBI presses ranging from 28 – 75 tons– Two Side Presses, 30 & 60 tons

• Fourslide Press– Complex bend combinations

• Brake Presses– Five (4 are CNC)

• Shear Presses


PROTOTYPE FORMING

• Kick Presses (104)– Prototype and Short Run


CAPABILITIES

• Photo Chemical Milling and Etching

• Extensive inventory of ferrous and non-ferrous raw material is maintained.– CRS, SS, Cu, BeCu, Phosphor Bronze, Aluminum, Brass– Nichrome, Kovar, Monel, Inconel are available per project needs– .002” - .125” Thick– Various Hardness’


CAPABILITIES

• Electroplating

• Heat Treating– In house for BeCu ONLY. Small batches/prototypes.

TYPE SPECIFICATION100% Tin (Sn) ASTM B545 (MIL-T-10727) Bright or Matte

Sulfamate Nickel (Ni) QQ-N-290A (AMS 2403), Class 1 and 2Gold (Au) ASTM B488 (MIL-G-45204), Grade C, Type I and II

Copper (Cu) AMS 2418F (MIL-C-14550 B)


CAPABILITIES

• Laser Cutting– Coherent 1000 System– Ferrous and Non-Ferrous Metals up to 1/8” thick– Various plastics up to 1/4” thick– Ideally suited for low volume/high mix projects


CAPABILITIES

• Forming and Drawing


CAPABILITIES

• Small Assembly

Heat Staking

Soldering

Wiring

Spot Welding


CAPABILITIES

Complex

Prototype

Metal Fab


VALUE ADDED SERVICES

• It all starts with design!– DFM/DFA design assistance early in the process– 2D and 3D CAD services

• Project Management from Quote to Delivery• Tool & Fixture Design and Build• Contract Services– Single sourcing/purchase order if we do the assembly or we

need specialty capabilities– Injection Molding, Insert Molding, Over Molding, Wire EDM

Blanks, Water Jet Blanks, Electroplating & Anodizing, Special Heat Treating, Machining, etc.


THANK YOU!

We appreciate the opportunity to tell you our story!


TECHNICAL PRESENTATIONPART 1


PROTOTYPING

• From Qty. 1 on up.• Must balance these factors or tell us what the

priority is:– Cycle Time (How fast do you need parts in your hand?)– Cost of Tooling– Cost of Piece Part– Method of Fabrication

• For prototype – does it really HAVE TO BE a drawn part?– Are you open to suggestions on alternatives in both

design and/or materials?


PHOTOCHEMICAL ETCHING

• Process used for manufacturing of thin gauge metal blanks that are later formed.

• Tooling consists only of photo tool typically costing $120 - $400.

• Standard raw material sheet size for this process is either 12” x 12” or 12” x 24”.

• We process from qty. 1 to as many as will fit on a sheet and price based on sheet usage.



• STARTS WITH CREATING A FLAT BLANK


COMPLEX BLANKS

• COMPLEX DRAWN BLANKS ARE CREATED


FLAT PATTERN ANALYSIS

• MESH AND ANALYZE


THICKNESS ANALYSIS

• THICKNESS VARIATION


DRAWN PART BLANK

• FLAT PATTERN RESULT


FORMED PART

• MANUFACTURED PART



• Tolerances to ± .0005” are achievable.• Recommended minimum inside radii to be 2/3

material thickness (1x preferred).• Minimum hole diameter or slot width is

recommended to be material thickness.• Selective or half etching is available for

engraving details or to create bend lines for post forming.


ETCHING PROCESS

1. Flat pattern of part blank2. CAD layout of etch sheet for maximizing material utilization 3. Dark room processes to create photo tool 4. Raw material Preparation 5. Lamination of material and photo tool(s)6. Exposure 7. Developer8. Etching9. Stripping


PHOTO TOOL

• STANDARD PROCESS SHEET SIZES– 12” X 12”– 12” X 24”


RAW MATERIAL

• IN STOCK OR SPECIAL ORDER– MATERIALS THAT WE CAN ETCH

• CRS• CARBON STEEL• STAINLESS STEEL• COPPER• BERYLLIUM COPPER• PHOSPHOR BRONZE• ALUMINUM• INCONEL• MONEL• KOVAR• NICKEL SILVER

– THICKNESS RANGE OF RAW STOCK

• .003” - .050”


LAMINATION

• PREPARATION FOR PHOTO EXPOSURE


EXPOSURE

• The laminated material is inserted between the phototools and exposed to photographic light to imprint the design on to the metal


DEVELOPMENT

• The exposed material is chemically treated to wash out the laminate from the part design after exposure


ETCHING

• FULL OR HALF ETCHING


STRIPPING

• The laminate is fully stripped off the finished parts


FINISHED BLANKS

• Photo Chemical Milling and Etching

• Electroplating is an optional next step


TECHNICAL CONCLUSION

• If you are unsure – call us or send us a file for review. There is much more to consider than the few examples shown in this presentation.

• We are the experts in optimizing for manufacturability.

• The benefit to you is lower cost with high precision and short lead times.


TECHNICAL PRESENTATIONPART 2


DIMENSIONING

• What’s the problem?

$


DFM

• Photo Etching Don’t – Line to Line

– Minimum gap of 1x material thickness recommended


DFM

• What is bend relief?

– Bend relief eliminates tearing.


DFM

• Forming Near Holes

– If it absolutely has to be that close to the bend, it will be done as a secondary operation which means it will cost more.


BENDS VS. FORMS

• 3D Modeling in Solidworks Sheetmetal App– Geometry must be of uniform thickness– Auto “flat pattern” requires geometry across the

bend area to be a plane, a cylinder or a cone. This is a Solidworks limitation (Pro/E as well).

• Everything else is a “form” feature.


DESIGN FEATURES

• Good Inside Corners (no material overlap)


DESIGN FEATURES

• Bad Inside Corner (not possible)


DESIGN FEATURES

• Good Outside Corners


DESIGN FEATURES

• Bad Outside Corners

NO BEND RELIEF


DESIGN FEATURES

• Cover and Frame Corner


DESIGN FEATURES

• Dimples – Grounding and Locking


GOOD CAD WORK

• Good 2-Piece Design Example– Proper Relief– No overlapping geometry– Parts designed for snap assembly


DESIGN FEATURES

• Parts With Drawn Features or Drawn Covers

• Expensive Tooling• Extended Lead Times• Consider Alternative for

Prototype Needs• Fabricate and Weld• Machining• 2-Part Assembly

• > 3x Mat’l Thickness = Deep Draw

• Blank Development requires 3rd party analysis tools


DESIGN FEATURES


DESIGN FEATURES

• Complex Drawn Shield


TECHNICAL CONCLUSION

• If you are unsure – call us or send us a file for review. There is much more to consider than the few examples shown in this presentation.

• We are the experts in optimizing for manufacturability.

• The benefit to you is lower cost with high precision and short lead times.

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Faspro Technologies - General 9.2013

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