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Case Study #1 - Industrial Appliance Industry

Customer Issue:
Manufacturing Paint Screen Pick-Up Tube was a labor intensive manufacturing operation as an operator hand loads mesh into the mold and then a plastic frame was molded around it. Previous construction of this paint screen is pictured on the right.

NMC Solution:
Design and construct a four cavity mold to produce injection molded one piece filters. The mold had to run fully automatic with an overall cycle of less than 30 seconds. To meet this challenge, NMC engineered a very complex mold containing 16 separate stainless steel slides in a cantilever design and all on radial shutoffs. The cooling requirements for this part and mold were another challenge, with baffles in each core and ejector pins running right through the water lines in certain areas. Venting was accomplished through vent pins and core laminations.

The Payoff:
With an average annual output of over 1,000,000 units/year, the return on tooling investment was approximately six months. NMC helped our client reduce their cost per unit by 73% and has since produced well over 5,000,000 pieces from this unique tool!

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Case Study #2 - Automotive Industry

Customer Issue:
Manufacturing oil screen assembly which consisted of a three-piece design with an insert molded mesh screen

NMC Solution:
This transfer case filter and pickup tube assembly posed yet another worthy challenge for NMC. Shown in the photo on the right (assembled/unassembled), this unit features 1,750 filter holes measuring .025" in diameter. The tube and screen are molded separately in four cavity molds with 33% glass filled nylon and the tongue and groove welding joints have a wall thickness of .010".

The Payoff:
NMC engineers converted a three-piece design with an insert molded mesh screen into this radically more effective and inexpensive two piece model. Still being run at volumes of nearly 3,000,000 units a year, NMC has provided tens of millions of assemblies without a single customer return!

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Case Study #3 - Home Appliance Industry

Customer Issue:
Carpet cleaning filters had serious quality and filtration problems with previous design

NMC Solution:
The part shown to the right is a filter for a carpet cleaning system and is molded in one piece using unfilled acetal resin. It features over 250 - .015" diameter holes spaced .011" apart.

The Payoff:
Produced in a four cavity mold, it has an annual volume of over 800,000 pieces and helped one of NMC's customers solve a serious quality and function problem with the previous design!

 
NMC IS AN ISO/TS 16949 CERTIFIED COMPANY
phone: 608-635-7366 • fax: 608-635-7371 • service@nonmetallic.com
 
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