www.webermfg.caISO 9001:2000 REGISTERED
Precision Tooling for Composite Processes
www.webermfg.caISO 9001:2000 REGISTERED
OverviewFounded in 1962, Weber Manufacturing Technologies Inc. is a leading manufacturer of precision
tooling for Automotive, Aerospace, and Home/Building Products.
Located in Midland, Ontario, Weber is a privately held Canadian company.
Weber offers high quality tooling in steel, invar and aluminum.
Over the last 20 years, Weber has offered nickel shell tooling using the Nickel Vapor Deposition
(NVD) process. This process is also used for capturing fine surface detail, such as leather and wood
grains, and authentically replicating them into hard tools.
200 employees, 135,000 sq. ft. facility
Certified ISO 9001:2008
On-site CAD Design (UGS, CATIA V5R20)
Modern simultaneous 5-Axis CNC machining centers
Full complement of CNC contour mills, gun-drills, vertical mills, and EDM machines
Canadian Controlled Goods Program registered (Satisfies US-ITAR requirement)
www.webermfg.caISO 9001:2000 REGISTERED
• Invar
• Steel
• Aluminum
• NVD Nickel Shells
• Billet, Castings and Welded construction
HARD SURFACE MOLDS
Invar 36 tool – welded
66,000 lb. P20 Steel billet – 5axis machining
www.webermfg.caISO 9001:2000 REGISTERED
Successfully completed numerous tooling programs (Invar, Steel, Nickel and Aluminum)
Full design, from customer part model file, to tool and fixture drawing packages
SAMPLE WEBER PROGRAMS
Example of INVAR
lay up tool for
deep part
CAD design for
welding 5 pre-
shaped sheets
together on frame
Close up of
INVAR
surface finish
quality
AEROSPACE APPLICATIONS
INVAR TOOLING
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INTERNALLY COLLAPSIBLE ATL MANDREL
• Weber has successfully worked with
Automated Dynamics on challenging projects
• Such as designing and building this multi-piece ATL
tooling for an Aircraft Fuselage Test Section
AEROSPACE APPLICATIONS
www.webermfg.caISO 9001:2000 REGISTERED
4 cavity single vane RTM molds
Multi tool program
CFM56-5B
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Multi cavity, single vane RTM mold
• Heated Coffin or Cavity
• Inner Guide Vanes
• Outer Guide Vanes
• Flow Path Spacers
• Fan Blades
• Platforms
RTM TOOLING - Steel
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Steel insert details:
Precision 5 axis machining
RTM TOOLING - Steel
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•Jet fan splitters
•Large round multi-piece tooling
•Updated manufacturing process
•Reverse engineered to confirm existing drawings
•Integrated fluid heated design to eliminate
ovens and permit stationary tool layup, debulk
and cure.
RTM PROCESS – Aluminum
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Fan Case tool being closed
Cast in heating lines visible in core section
RTM PROCESS – Cast Aluminum
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MAN Truck Roof Manufactured By Fritzmeier Composites Assembly of Nickel Shell to Mold Base
Received Innovation Award
for Best
Industrial Application 2000
Complete Nickel Shell Mold
• Multi tool program for several versions of cab roof
• 2 NVD nickel shells, 18 mm thick, welded together
for each core and cavity, on steel support frames
• Low weight solution for long life, uniform heating
• ~ 100” square, 30 “ deep part
RTM PROCESS - NVD SHELLS
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• Nickel cure tools for processing Polyimides such as PMR15 material
• Weber is a Boeing Approved Tool Supplier
• Nickel tools for Boeing 737, 777, 787-8 and 787-10 leading edges
• Nickel tools with removable steel inserts for C-Series flap track fairings
•Weber is Bell QPS111 Approved
AEROSPACE APPLICATIONS
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AEROSPACE APPLICATIONS
LAY-Up TOOLING FOR AUTOCLAVE
ie: LM AND BAJ
• Nickel tool for deep parts such as airfoil leading edges
• Tubular steel or eggcrate frame construction
• This tool is designed to adjust for spring back changes during production
www.webermfg.caISO 9001:2000 REGISTERED
LAY-UP TOOLING
• Multi Tool Autoclave Program of Nickel Lay up tools for Sikorsky Black Hawk UH60M
• Aluminum collapsible
APU duct tooling
AEROSPACE APPLICATIONS
www.webermfg.caISO 9001:2000 REGISTERED
•No welding of the shell to the frame.
•Perimeter standoffs are pre-machined as
round counter-bored blanks and placed on
deposition mandrel.
•The shell is placed on the welded frame
and screwed into position.
Nickel Shell Design
•Encapsulations for tooling holes
•Encapsulations for vacuum
through the shell
www.webermfg.caISO 9001:2000 REGISTERED
Shell Design - View through side of eggcrate frame
NVD Shell
Frame
Push Pull Support
Spot Welded Studs
Vacuum Line
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- NVD shell tooling - high strength and lightweight
- Flexible tool design options including:
• Undercut geometry
• Encapsulated features for mounting and location, injection, ejection, shear edges, mechanisms, etc
• Welded shell construction for very large parts
- For Multiple Molds, Replicate Cavities:
• Are identical
• Cost less than alternative machining
• Are easy to replace if damaged
• Replacement timing is weeks
NVD SHELL TOOLING FEATURES
• Trim and drill fixture packages
• Welded and machined aluminum roof bonding tool for 407 helicopter
• 220” Aircraft floor beam machining
fixture, with vacuum holding
FIXTURES and MODELS
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• Aluminum prototype models for VLJ development
• Production fixtures for windscreen assembly
• ‘Soft’ Master models
FIXTURES and MODELS
• Vane Machine Fixture
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INTEGRALLY HEATED TOOLING:
• OUT OF AUTOCLAVE
• OUT OF OVEN
• SELF HEATED
ISO 9001 : 2000 Registered
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www.webermfg.caISO 9001:2000 REGISTERED
Heat Transfer: Our History and Experience
• Various customized production processes have been developed and implemented into Weber tooling over the last 10 years
• Mold surface temperatures can be steady state, or rapid cycling per part
• We have implemented:
• Piping lines buried in high strength epoxy
• Piping lines encapsulated with a layer of NVD nickel
• Piping lines w Thermal arc spray of Copper or Silver
• Liquid directly on back of surface in conformal flow against the surface
• Piping lines soldered onto the back of a NVD shell
Weber’s recommendation: the most cost effective way to produce a rapidly changing tool surface, on a 6–10 mm thick shell is:
» Soldered lines on the back of a NVD shell
Out of autoclave, and resin infusion processes benefit from rapidly changing, uniform temperature distribution on tooling surfaces
Let Weber produce the system you need.
www.webermfg.caISO 9001:2000 REGISTERED
• We have hundreds of self heated tools in production for thermally demanding processes
• Automotive Door & IP skins for BMW, Chrysler, Ford, GM, and Mercedes interior parts.
• Rapid temperature cycles: 40C (100F) to 200C (400F) in minutes …….
Heat Transfer: Rapid and uniform heat movement
Weber OOA tooling
knowledge is built on
many years of delivering
heated molds to the
Automotive Interior Market
• 3mm thick NVD
• Textured nickel shells
• Various heating styles
Several examples are
shown in the next few
pages use this tool
technology
www.webermfg.caISO 9001:2000 REGISTERED
OUT-OF-AUTOCLAVE PROCESS w SELF HEATED TOOLS
• Use of NVD shells for layup tools
• Inside each self contained tool are:
• Heating / cooling lines
• Through tool vacuum system
• Fluid and Vacuum Manifolds
• Thermocouple wiring
Wing fillet tool converted to an
out of autoclave format for trials
AEROSPACE
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OUT-OF-AUTOCLAVE PROCESS w SELF HEATED TOOLS
• Use of NVD shells for Class A
automotive Hood and Roof
• Inside each self contained tool:
• Heating lines
• Vacuum lines
• Thermocouple wiring
• Globe Press interface
• Swing out inserts
•(US Patent 8545662 B2)
Multiple “Class A” Identical molds
from a precision mandrel
Winner of 2013 SPE Auto Innovation Award
AUTOMOTIVE
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• Conformal temperature distribution using water
• Piping for heating/cooling attached to back of 8mm shell
• Rapid temperature response capability
TRUCK
OUT-OF-AUTOCLAVE PROCESS w SELF HEATED TOOLS
www.webermfg.caISO 9001:2000 REGISTERED
DESIGN &
MANUFACTURING
ISO 9001 : 2000 Registered
www.webermfg.ca
ISO 9001 : 2008
• Extensive CAD/CAM capabilities
• 10 workstations running:
• UG-NX, IDEAS, Catia
• Innovative designers are working with customers to contribute to processes and provide tooling solutions.
• Our team manages all information and supports the machining, assembly and CMM teams.
• Strict revision control on all documents and designs.
• Part of the Weber focus of building relationships and responding to customer needs.
• CAD data transfer in:
1. STEP, IGES and VDA (BI-DIRECTIONAL)
2. IDEAS NX5 (NATIVE)
3. CATIA V5-R23 (NATIVE)
4. UNIGRAPHICS NX8 (NATIVE )
5. SOLID-EDGE ST4 (NATIVE)
TOOL DESIGN
ISO 9001 : 2008
PROGRAM MANAGEMENT
• On Time deliveries are paramount at Weber.
• Manufacturing schedules reviews conducted weekly.
• Progress reports are sent to customers bi-weekly.
• In House transportation within North America.
• Global customs expertise - We export and import responsibly.
www.webermfg.caISO 9001:2000 REGISTERED
• Quality standard is ISO 9001:2008
• Canadian Controlled Goods Program (CCGP) for participation in US - ITAR projects
• Registration No. 22921
• CWB W47.1, W59.1 Welding certificates
• D6-56202 – Boeing Tooling Supplier
• QPS 111 – Bell Helicopter Tooling Approved
CERTIFICATIONS
Manufacturing and Mold Making
Departments
Weber’s Pattern Shop, Machining, Fabrication and Assembly bays
suit all shapes and sizes of tooling projects
Equipment Highlights
• State of the art machining.
• Hypermill 5- Axis software.
• 590 in/min max cutting speed
with 8,000-10,000 RPM.
• Machining aerospace parts
Five 5-Axis Deckel Maho Machining Centers
Equipment Highlights
Ingersoll Master Mill
• 5-Axis simultaneous capable.
• 5 different cutting head
attachments. 4,000 -10,000
RPM. All automatically loaded
and unloaded.
• Large work envelope
• X-236 inches
• Y-137 inches
• Z-40 inches
• Table capable of taking 88,000
pound block.
• Utilizes HyperMill/PowerMill
Machining Software.
• 2 Computer Controlled CMM’s
• Certification of Models, Tooling Aids, Molds,
Steel & Finished Parts to Math Data
• Diffracto Class-A Surface Quality Verification
• Certificate of Conformance
• Detailed Inspection Reports sent to Customer
QUALITY ASSURANCE
www.webermfg.caISO 9001:2000 REGISTERED
IN HOUSE FABRICATION, ASSEMBLY,
PATTERN SHOP
AND HANDWORK
www.webermfg.caISO 9001:2000 REGISTERED
Customers from around the world
choose Weber to take advantage of:
1. EXPERIENCE - Over 54 years of mold-making experience producing a wide
range of large, class A, custom mold solutions in P20 steel, NVD Nickel, Invar
and Aluminum.
2. INNOVATION – Design knowledge gained from experience in various
competitive markets is continually applied for new engineering developments.
3. CAPACITY & CAPABILITY – Large, fully integrated Mold Design and
Manufacturing Shop can handle large tools, and manage large, multiple tool
programs efficiently, and professionally.
4. NVD NICKEL SHELLS – A unique mold making material, NVD nickel shell
tooling provides an alternative for rapid, accurate, high quality composite
production. Class A surfaces and conformal heating & cooling designs support
shorter cycle times and uniform mold face temperatures.
www.webermfg.caISO 9001:2000 REGISTERED
16566 Highway 12
P.O. Box 399
Midland, ON L4R 4L1 CANADA
Tel:
Fax:
Web Page:
(705) 527-2930 [Main]
(705) 526-3818
http://www.webermfg.ca
Direct:
Mobile
Email:
SALES OFFICES
GERMANY
Thomas Helle
European Sales Agent
Tel:
Mobile:
Email:
+49 (0) 7021 978 558
+49 (0) 171 637 7550
HEAD OFFICE
Tom Schmitz
Business Manager
(705) 527-2956
(705) 527-2154
Greg LeidigU.S. Sales Agent
Mobile:Email:
(419) [email protected] STATES of AMERICA