Aerospace

• 1. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 Feb 2013 Precision Tooling for Aerospace Composites

2. ISO 9001 : 2008 Overview Founded 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, and precision CNC machined aluminum parts. 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. 140 employees, 135,000 sq. ft. facility Certified ISO 9001:2008 On-site CAD Design capable (UG NX, 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) 3. ISO 9001 : 2008 COMPOSITE CUSTOMERS 4. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 TOOLING PACKAGES: Example - BOEING 787 300 tools = Lay-up Molds, Trim & Drill Fixtures and Hot Drape Form Tools (Invar, REN Board and Aluminum) 5. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 FIXTURES and MODELS DIAMOND JET Aluminum / REN bond tools, fixtures and prototypes 6. ISO 9001 : 2008 Invar 36 Steel Aluminum NVD Nickel Shells Billet, Castings Welded Construction TOOLING MATERIALS Welded Invar 36 tool Aluminum and Nickel: tools and parts Weber offers a range of materials and experience for your tooling requirements 7. ISO 9001 : 2008 Examples of aluminum or steel matched molds for press molding of interior Aerospace panels Ask for the Weber presentation on high pressure SMC tooling or Automotive interior tooling AEROSPACE APPLICATIONS 8. ISO 9001 : 2008 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 9. ISO 9001 : 2008 Bell 429 Completed nose cone tool and frame +120 other tools AEROSPACE APPLICATIONS 10. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 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 PROCESS APPLICATIONS 11. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 LAY-UP TOOLING Weber is a Boeing Approved Tool Supplier Nickel tools for 787-8 leading edge of vertical stabilizer PROCESS APPLICATIONS 12. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 LAY-UP TOOLING Multi Tool Program of Nickel Lay up tools for Sikorsky Black Hawk UH60M PROCESS APPLICATIONS Aluminum collapsible APU duct tooling 13. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 NVD Nickel Lay up tool for high temp Polyimides >300 Celsius (600F process) Nickel Shell Application PROCESS APPLICATIONS 14. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 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 15. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 Trim and drill fixtures Production assembly fixtures for windscreen Welded and machined 407 bonding fixture Soft Master models FIXTURES and MODELS 16. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 MACHINING FIXTURES 220 Inches Aerospace Machining Fixture With Vacuum Holding A2C2 Double Vane Machine Fixture A2C2 Doublet Bond Fixture A2C2 Single Vane Machine Fixture 17. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 PRESS TOOLING Pratt and Whitney PW4168 Acoustic Panel Sections Innovative Weber tool design Multiple parts and steel tools Tools mold-in >3700 holes into the part Inspection fixture and preform tools also supplied by Weber 18. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 Jet fan spinners 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 tooling 19. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 RTM PROCESS Full tool being closed 20. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 RTM PROCESS PRATT & WHITNEY Pratt F117-PW-100 engine for C-17 Jet fan splitter Large round multi-piece tooling Updated manufacturing process Reverse engineering to confirm existing drawings Integrated Oil heated design to eliminate ovens 21. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 3 cavity single vane RTM mold Coffin and cross sections RTM PROCESS Steel Tools 22. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 4 cavity single vane RTM mold 23. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 OUT OF AUTOCLAVE See separate presentation ISO 9001 : 2000 Registered www.webermfg.ca ISO 9001 : 2000 Registered www.webermfg.ca 24. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 Conformal temperature distribution using water Piping for heating/cooling attached onto back of 8mm shell Rapid temperature response capability 75 C/min (135 F/min) OUT OF AUTOCLAVE PROCESS Thermal performance 25. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 NVD OPERATIONS ISO 9001 : 2000 Registered www.webermfg.ca 26. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 Worlds largest Nickel Vapor Deposition facility Modern, computer controlled plant, built in 2000 400,000 lbs annual Ni deposition capacity NVD nickel is 99.98% pure 1.74m X 3m shell size capacity Speed is 0.25mm per hour, 6mm in 1 day. Superior process to Electroformed Nickel NVD NICKEL PRODUCTION FACILITY Chemically convert nickel to solid shapes 27. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 - 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 28. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 NVD SHELL BASED TOOLING OFFERS Conformal Heating/Cooling -> Faster cycle time Uniform nickel shell wall thickness -> Improved thermal distribution Mold release -> Fine grain structure Mold durability -> 34 38 Rc hardness Weldability > allows for repairs or joining of multiple shells Fast Process (0.25 mm/hr) -> in 1 day ! Reusable mandrel for duplicate shells -> Repeatable accuracy Short duplicate shell delivery times -> ~ 2-4 weeks Significant cost savings for duplicate shells CNC Machined Metallic Mandrels -> Accurate shells, greater part quality NVD Shells are virtually stress free -> Accurate shells 29. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 Material P20 Tool Steel Aluminum Invar NVD Nickel Density lb / in3 0.282 0.098 0.293 0.322 kg / m3 7800 2720 8130 8910 Yield Strength psi 143000 7980 40000 61400 MPa 990 55 276 411 Stiffness psi 30 x 106 10 x 106 21 x 106 17 x 106 GPa 205 70 145 114 Thermal Expansion in / in oF 7.0 x 10-6 12.9 x 10-6 0.7 x 10-6 7.2 x 10-6 mm / mm oC 12.6 x 10-6 23.6 x 10-6 1.3 x 10-6 13.1 x 10-6 Thermal Conductivity Btuin Ft2hr oF 201 1452 73 610 W / m oC 29 210 11 88 Hardness Brinell 270-480 20-160 120-180 330-380 MATERIAL PROPERTIES 30. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 NVD NICKEL VS ELECTROFORMED SHELL 1. 25mm per 2000 hr deposition rate 2. Shell thickness is not uniform 3. Inherent residual stresses 4. Cavities made simultaneously from different mandrels 5. Problematic variation from cavity to cavity 6. Replace damaged shell in 16-30 weeks 7. Cannot do hollow 8. Sulfates contamination from electroplating bath = difficult welding + de-lamination risk 1. 25mm per 100 hr deposition rate 2. Uniform thickness & temperature 3. Negligible residual stress 4. Cavities made sequentially from the same mandrel 5. Little variation from cavity to cavity 6. Replace damaged shell in 3 weeks 7. Hollow deposition possible in many cases 8. 0.999 pure Ni weldable and no de- lamination 9. No environmental impact (closed system) 31. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 DESIGN & MANUFACTURING ISO 9001 : 2000 Registered www.webermfg.ca 32. www.webermfg.ca ISO 9001:2000 REGISTERED 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 V5R20 (NATIVE) 4. UNIGRAPHICS NX6 and NX7.5 (NATIVE ) 5. SOLID-EDGE V20 (NATIVE) TOOL DESIGN 33. www.webermfg.ca ISO 9001:2000 REGISTERED 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. 34. ISO 9001 : 2008 CERTIFICATIONS Quality standard is ISO 9001:2008 Registered with Canadian Controlled Goods Program - Registration No. 22921 CWB W47.1, W59 Welding certificates 35. ISO 9001 : 2008 Weber is Certified to CSA Standard W47.1 by The Canadian Welding Bureau Approved for participation in the Canadian Wood Products Certification Program (CWPCP) Registration Number: CA-00047 D6-56202 Approved Boeing Northwest Provisioner Tooling Supplier CERTIFICATIONS 36. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 Manufacturing and Mold Making Departments Weber has a large number of Machining, Fabrication and Assembly bays to suit all the shapes and sizes of your tooling 37. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 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 38. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 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. 39. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 Equipment Highlights Droop & Rein Copy Mill Large load capability - 66,000 pounds. Twin Spindle simultaneous mirror image machining capability. Excellent for roughing. Large machining envelope X- 138 Inches Y- 117 Inches Z- 33 Inches Cutting Software Powermill. 40. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 CNC GUNDRILLS Equipment Highlights 41. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 ASSEMBLY BAY SET UP FOR MULTIPLE MOLD BUILDS 42. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 2 Computer Controlled CMMs 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 43. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 REN or epoxy models Manufacturing of patterns for casting of aluminum face sheet or mandrels Aluminum castings can include cast-in-place heating/cooling lines if required IN HOUSE PATTERN SHOP 44. ISO 9001 : 2008 In House Handwork Handwork Department Deals With Steel, Aluminum, Nickel, & Invar Molds Webers Handwork and Polishing Department can handle all types of mold finishes including Class A and High Diamond Polish 45. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 Equipment Highlights Tryout Presses Wemhoner 3250 ton Fully rebuilt in 2005/6 Steam and Oil Heating capability Full vacuum system for molding Class A SMC panels Ott 500 ton Steam and Oil Heating Capability Vacuum system 46. www.webermfg.ca ISO 9001:2000 REGISTERED ISO 9001 : 2008 Customers from around the world choose Weber to take advantage of: 1. EXPERIENCE - Over 45 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. 47. ISO 9001 : 2008 16566 Highway 12 P.O. Box 399 Midland, ON L4R 4L1 CANADA Direct Mobile: Email: (705) 527-2976 (705) 527-2123 [email protected] Tel: Fax: Web Page: (705) 526 -7896 [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] Robert Sheppard Vice President Greg Leidig U.S. Sales Agent Mobile: Email: (419) 481-3645 [email protected] UNITED STATES of AMERICA