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Presents:

- Introduction to PERNOUD Group & AGP Development

- Multitube® (Molding) Innovation

- Multi-Process Mold (Molding) Technology (MPM)

- Improvement of existing (Molding) Processes

www.pernoud.com

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Over 100 Employees

$ 13.8 Million Annual Sales

Business Share

Automotive 70%

Building 20%

Others 10%

Management, Sales, Purchasing, … 10

R&D 2

Design (incl. Methods planning) 5

Work scheduling (incl. Programming) 10

Production 49

Workbench - Assembly – Trials 9

Quality Insurance 3

Ind. Dept. (technical & incl. project mgr.) 8

Ind. Dept .(administrative) 4

Total Employees 100

France France Slovakia USA

www.pernoud.com

Annual Sales 2014-2015

Shareholders Equity 1.6 Million USD 1.5 Million €

Annual Turnover 13.8 Million USD 12.5 Million €

Gross Margin 25% 25%

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www.pernoud.com Global Turnover Breakdown / Business Unit:

Total Industrial Areas: 4,650 m2 (50,050 sq ft)

Over 1,500 molds designed and produced. (tool sizes up to 10 tons)

Family owned : Gilles and Philippe PERNOUD

45 years experience

Expertise in Multi-Process Molds and Multitube® Technology

Key Figures

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the Support

R&D Dept.

Prototyping, Manufacturingof micro-series

Tool Design and Manufacturing in France & LCC including equipment:

• Integrated Design Office (CAD 3D VISI MOULD / FAO WORKNC)

• Project Managers Dept.

• 5 axis high capacity Milling Center

• 5 axis Milling Center with robot cell

• CNC Turning Center

• EDM and Wire EDM

• CNC cylindrical grinding and profile

• 3D measurement control

Improvement, Follow-up,

Modification, Life series in France &

Slovakia

Development of MULTITUBE®

Innovation & MPM Technology in the

U.S.

www.pernoud.com

CLIENT

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Speciality: Multi-material and High gloss plastic parts

Main Business Sector: Automotive – Exterior parts

Expertise: Index Plates, Multi-Layers injection, IMA®

Speciality: Technical and Aesthetical plastic parts

Main Business Sector: Automotive – Under Hood parts

Expertise: Multi-Process Mold (MPM), Multitube®

Sales

Purchasing

Subcontracting

UNITING FORCES AND PERFORMANCE MOLDS

>> 3 Tool Shops – 3 sources of expertise

The 1st French moldmaking cluster sharing the following activities: 33%33%

33%

Speciality: High speed molding and Extra thin wall parts

Main Business Sector: Food and Industrial packaging

Expertise: Thermal cooling of tools, In Mold Labelling

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Accredited Research Center by the French Ministry of

Higher Education and Research

Years 2014, 2015 and 2016

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PEZINOKo Productiono After Sales Serviceso Tests Centero Sales Office

RHÔNE-ALPESo Headquartero R&Do Productiono Tests Centero Sales Office

PORTUGALo 6 Low Cost Partnerso Production

RHÔNE-ALPESo Immersion wire cuttingmachineRHÔNE-ALPES

o Prototypingo Manufacturing of micro-series

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CHINA 6 Low Cost Partnerso Production

(Molds up to 12t.)o Tests Center

(Presses up to 2000t.)

• Plastic Injection• Maintenance

INDIA• Design Office• 3D & 2D drawings• 5 engineers

Factory

• Sales Office

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NPE 2015 Orlando - USA

K 2016 Düsseldorf - Germany

FAKUMA 2015 Friedrischafen - Germany

AMERIMOLD 2016 -Detroit - USA

FIP 2017Lyon - France

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• Mold bonding areas, both chemical and mechanical, that allow the assembly of

multiple components within the mold in order to produce a complete finished

part

• Available for applications using standard (single barrel) or multi-material

injection molding machines utilizing multiple barrels

• Components are transferred within the mold by EOAT or rotary plate

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The sample part shown is an example of Multitube® technology

• Product :

• Air Intake Manifold

• Operations performed:

• Cover overmolded by Multitube® technology (transfer by EOAT)

• Overmolding of 4 metal inserts to assemble the plate (placed by EOAT)

• Overmolding of a gasket in TPE resin to seal the connection plate.

(by an additional injection unit attached to mold, E-multi from MoldMasters)

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Overmolding of a gasket

Progress of Development…

MULTITUBE® Concept

• Multiple components are joined within the mold with

molded bonding areas (both chemical and mechanical)

that allow the delivery of a finished product each shot.

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PP GF20 + PP GF20

PP GF20 + SEBS

PA6.6 GF35 + PA6.6 GF 35

PA6.6 GF35 + PPA

Examples of Resin Compatibility:

Tests configuration : water + glycol from 120°C (248°F) to 160°C (320°F)

PPS + PPS

PA6 + PA6 SOFT

Preliminary Testing of bonding is performed on sampling mold to confirm resin compatibility

InsertOvermolded

Part

Bonding Area

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The Multitube® seal is obtained by fusion of the part located on the insert.

The mechanical strength is done by the recovery of materials.

Validation of the aging parts

- In an Oven

- Filled by glycol and water

Test Description:

Multitube® parts are submitted

to 2.5 bars (36.3 psi) pressure

at 120°C (248°F)

Original Part

After 450h Static

Pressure

After 450h Dynamic

Pressure (in cycle)Inspection: by Micrographic Analysis

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Test Conditions:

• Water pressure increments until failure

• Step pressure: 2 bars (29 psi)

• Maintaining level: 1 minute

Test nr 1:

• Part Temperature: 20°C

(68°F) 24h

• Resin: PA 66.6 GF 30

• Water Temperature: 18°C (64°F)

• Failure pressure: 16-18 bars

(232-261 psi)

Test nr 2:

• Part Temperature: -40°C

(-40°F) 24h

• Resin: PA 66.6 GF 30

• Water Temperature: 5°C (41°F)

• Failure pressure: 16-18 bars

(232-261 psi)

Test nr 3:

• Part Temperature: 140°C

(284°F) 24h

• Resin: PA 66.6 GF 30

• Water Temperature: 80°C (176°F)

• Failure pressure: 11-13 bars

(160-188 psi)

17Example: RAMPE K4M ECOTECH, Production Part

Vibration Welding

Initial Design

MULTITUBE® Concept

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FUNCTION of the part:

- Circulation of Engine Cooling Fluid

MATERIAL:

- PA 6.6 GF35

CONCEPTION:

- 2 parts welded by vibration to enable the

stripping of complex shapes

PROCESS: 1+1 cavity mold

- Injection by sequential valve gating.

- Parts removed by EOA

- Positioning and set up on the welding unit

- Vibration welding

- Tightness controlled at 100%

- Parts cleaning

- Parts packed

FUNCTION of the part:

- Circulation of Engine Cooling Fluid

MATERIAL:

- PA 6.6 GF35

CONCEPTION:

- 2 parts assembly by overmolding in a

Multitube® mold

PROCESS: 1+1 cavity mold

- Injection by sequential valve gating.

- Parts moved and removed by EOA.

- Parts packed

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Classic Technology Multitube® Concept Gain / Difference

Resin cost per part 0,700 €0.957 $

0,525 €0.718 $

-25%

Value per part 1,341 €1.833 $

0,867 €1.185 $

Total Value + Resin

2,041 €2.789 $

1,392 €1.903 $

0,649 €0.886 $

Global Investments

160 000 €218 720 $

155 000 €211 885 $

5 000 €6 835 $

Qty of parts for Pay Back

- 7 705 parts

Gain in a full yearof production

227 124 €310 478 $

Gain after 5 yearsof production

1 140 622 €1 559 230 $

Basic data for this K4M

example:

350 000 parts / year

3,50 € / kg (4.78 $) of

PA6.6 GF35

2,041 € (2.789 $) cost per part with

classic technology

Press cost 880 €

(1 202 $) / day

5 years to produce

1 € = 1.367 $ (01/10/2014)

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Air Duct I4 Ford Transit, 1+1 cavity mold, transfer by EOA,

metal inserts, 420t. press, production in Argentina

Water Duct Fiat Idea + Muse (long version), 2+2 cavity mold,

transfer by EOA, production in France

Water Duct Fiat MDE (short version), 2+2 cavity mold,

transfer by EOA, production in France

Duct RAS – BP Mercedes M230 platform, 1+1 cavity mold,

transfer by EOA, production in France

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- In-Mold bonding, both chemical and mechanical, that allow the assembly of multiple

components within the mold in order to produce a complete finished part

- Available for use with standard (single barrel) or multi-material, multi barrel injection

molding machines

- Components are transferred within the mold by EOAT or rotary plate

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• 3 injected molded parts

• 2 welded spins

• 2 inserts assembly

• 1 seal assembly

Initial Design:

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• Realization of the seal groove

directly in the body has the effect

of creating traces of possible flash

due to the collapsible core and the

possible presence of parting lines

Initial Design quality issues:

• Unacceptable contamination

issues due to debri from the

spin welding

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• 3 molds

• 4 unique pieces of capital equipment

• 2 welding operations

• Necessary cleaning at welded joint of welding debri

• Inserts assembly

• Seal integrity testing by air pressure

Operational Processes required with Traditional Design:

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• The 3 parts are injection molded in a

single mold including the 2 overmolded

threaded inserts

• The link between the 3 parts is

realized by Multitube® Technology with

both mechanical and chemical bonding

• The 3 parts and the seal are

positioned into the assembly by EOAT

and a rotating core pin

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• The problem of contamination is eliminated

since the spin welding is no longer performed

• By means of design modifications, the both

parts do not require an undercut (collapsible

core) and thus eliminate the issue of flash

* All the mating interfaces between parts are realized by Multitube® Innovation

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A

D

C

B

1st step = Injection molding of components: A,B,C

2nd step = Transfer from A to D by EOA + the finished parts are ejected + the inserts are dropped in B position

3rd step = Rotation B and C + seal positioning + assembly

4th step = Injection and overmolding in D position

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• 3 molds

• 2 welding operations *

• Seal positioning /assembly

• Insert positioning /assembly*

• Cleaning operation for welding*

• Pressure test*

• Potential scrap of plastic parts

due to the welding process failure

* requires capital equipment use.

• 1 mold

TRADITIONAL DESIGN MPM TECHNOLOGY

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ClassicTechnology

MPM Concept Gain / Difference

Resin cost per part

1,260 €1.722 $

1,050 €1.435 $

16%

Value per part 2,019 €2.760 $

0,997 €1.363 $

Total Value + Resin

3,279 €4.482 $

2,047 €2.798 $

1,232 €1.684 $

Global Investments

215 000 €293 905 $

275 000 €375 925 $

60 000 €82 020 $

Qty of parts for Pay Back

48 709 parts

Gain in a full yearof production

431 133 €589 359 $

Gain after 5 yearsof production

2 095 665 €2 864 774 $

Basic data for this

MPM example:

350 000 parts / year

3,50 €/kg (4.78 $) of

PA6.6 GF30

3,279 € (4.482 $) cost

per part with Classic

Technology

Press cost 880 €

(1 202 $) / day

5 years to produce

1 € = 1.367 $

(01/10/2014)

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>> BEFOREWELDED PARTS FOLLOWING

CLIENT DESIGN

>> AFTERSINGLE PART DEVELOPED BY PERNOUD

for a FORD application

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>> AFTER SINGLE PART DEVELOPED BY PERNOUD

for MSA SAFETY application

>> BEFOREWELDED PARTS FOLLOWING

CLIENT DESIGN

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o Co-design of products• Part Design

• Moldflow Analysis

• Mold Design

o Innovative technical proposals:• Laser Sintering / Conformal Cooling

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Cooling System

Air Intake Manifold and Filters

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Surge TanksFuel Pump

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Interior / Exterior Parts

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On the traditional parts, basis conception

- We conduct the feasibility analysis with the MPM Technology / Multitube® Innovation

- We propose necessary part design modifications to realize the project >> Avg lead time: 1 week

- The Customer approves the changes in regards to the technical contraints of the final part design

- We define the following parameters:

Injection mold machine capacity

Part weight

Injection mold machine cycle time (estimation)

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- Study: MPM / Multitube® conception, validation and preparation of the part drawing and plastic resin

compatibility, established by Georges Pernoud SAS

- Construction of a prototype mold in France (or in some case by US Partner, not available for first project)

>> Avg lead time: 6 to7 weeks for the mold and 1 week to produce samples (not including transportation)

- The mold design is created with attention to securing movements and overall reliability.

- A tool maintenance program is created in detail (training available)

- A list of planned spare parts will be created and will be made available

- A detailed technical file is included with the delivery of the mold

- Construction of a production mold in France by Georges Pernoud SAS

>> Avg lead time: 18 to 20 weeks for the mold and 1 week to produce first samples (without transportation)

- The post sales service is realized by US partners (maintenance services in the US)

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North America Globally*

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Georges PERNOUD SAS

Parc Industriel La Prairie BP 90099 Groissiat F-01116 OYONNAX Cedex

www.PERNOUD.com