Precision Tooling for Composite Processes · • Extensive CAD/CAM capabilities •10 workstations running: •UG-NX, IDEAS, Catia • Innovative designers are working with customers

www.webermfg.caISO 9001:2000 REGISTERED

Precision Tooling for Composite Processes

http://www.webermfg.ca/


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)



• 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



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


INVAR36 TOOLING

(low CTE)

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

INVAR TOOLING



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




RTM TOOLING



4 cavity single vane RTM molds

Multi tool program

CFM56-5B



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



Steel insert details:

Precision 5 axis machining

RTM TOOLING - Steel



•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



Fan Case tool being closed

Cast in heating lines visible in core section

RTM PROCESS – Cast Aluminum



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



COMPOSITE LAYUP TOOLING



• 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





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



LAY-UP TOOLING

• Multi Tool Autoclave Program of Nickel Lay up tools for Sikorsky Black Hawk UH60M

• Aluminum collapsible

APU duct tooling




•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



Shell Design - View through side of eggcrate frame

NVD Shell

Frame

Push Pull Support

Spot Welded Studs

Vacuum Line



- 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



FIXTURES and MODELS


• 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


• Aluminum prototype models for VLJ development

• Production fixtures for windscreen assembly

• ‘Soft’ Master models

FIXTURES and MODELS

• Vane Machine Fixture



INTEGRALLY HEATED TOOLING:

• OUT OF AUTOCLAVE

• OUT OF OVEN

• SELF HEATED

ISO 9001 : 2000 Registered

www.webermfg.ca



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.



• 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



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




• 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



• Conformal temperature distribution using water

• Piping for heating/cooling attached to back of 8mm shell

• Rapid temperature response capability

TRUCK




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.


• 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


IN HOUSE FABRICATION, ASSEMBLY,

PATTERN SHOP

AND HANDWORK



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.



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

[email protected]

HEAD OFFICE

Tom Schmitz

Business Manager

(705) 527-2956

(705) 527-2154

tom [email protected]

Greg LeidigU.S. Sales Agent

Mobile:Email:

(419) [email protected] STATES of AMERICA


Documents

Precision Tooling for Composite Processes · • Extensive CAD/CAM capabilities •10 workstations running: •UG-NX, IDEAS, Catia • Innovative designers are working with customers