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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

WEBER MANUFACTURING TECHNOLOGIES INC.

Tooling for Automotive Interiors

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

COMPANY 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 offers high quality tooling in nickel, steel, invar and aluminum, and precision CNC machined aluminum parts. Over the last 15 years, Weber has developed 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 . 135 employees, 135,000 sq. ft. facility On-site CAD Design capable (UGS, CATIA) Certified ISO 9001:2008 Canadian Controlled Goods Program registered Modern simultaneous 5-Axis CNC machining centers Full complement of CNC contour mills, gun-drills, vertical mills, and EDM machines

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

HEAD OFFICE, MOLD MANUFACTURING, AND NICKEL VAPOUR DEPOSTION PLANT ALL LOCATED AT MIDLAND, ONTARIO, CANADA

PLANTS OVERVIEW

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

COMPANY HISTORY 1962

Established Weber Manufacturing (Windsor) Limited

1967

Relocated to a new building in Midland, Ontario Established the Weber Tool & Mold Division

1989

Established the Nickel Tooling Technology (NTT) Division

1991

Sold our first Nickel Shell

1998

Built and tested NVD Pilot Plant

1999

Designed and Built Large Scale NVD Plant

2000

Commissioned the NVD Nickel Division

2001

Produced our first Nickel Shell in February

2004

Company purchased by American Capital Strategies and TMB Industries

2007

Company purchased by Zynik Capital Corporation 4


ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

Automotive Interior

Automotive Exterior

Key Market Areas

Aerospace Key Market Areas

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Home & Building


ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

QUALITY CERTIFICATIONS • ISO 9001:2008 certified • Boeing Certified Supplier • Registered with Canadian Controlled Goods Program - Registration No. 22921 • CWB W47.1, W59 Welding certificates

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

QUALITY ASSURANCE ISO

9001:2008 Certified  2 Computer Controlled 5-axis CMMs  3 Full Time CMM Operator/Inspectors  Full Certification of Models, Tooling Aids, Molds & Finished Parts to Math Data  Steel Hardness Check on Incoming Blocks  Diffracto Class-A Surface Quality Verification  Detailed Inspection Reports sent to Customer  Mold Completion Check List

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

WEBER MACHINE CAPACITY Weber has a total of 32 large CNC machines; • 6 5-Axis CNC Mills

• 5 Droop & Rein 3-Axis CNC Mills

• 2 4-Axis CNC Mills

• 2 EDM Machines

• 3 Vertical Mills

• 3 Various Detail Machines

• 3 Tarus CNC Gun Drills

• 2 Vertical Presses

• 4 Horizontal CNC Boring Mills

• 2 CMM Measuring Machines

Weber also has various welding and checking tools; • Yag Laser Welder

• Profilometer

• Thermal Spray

• Hardness Testing

• Tig & Mig Welder

• Ultrasound Thickness Checking

• ARC Welder

• Thermal Imaging

• Aluminum Oxide, Glass bead and sand blasting.

• Laser Pyrometer 8


ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

EQUIPMENT HIGHLIGHTS Five 5-Axis Deckel Maho Machining Centers • State of the art machining. • Hypermill 5- Axis software. • 590 in/min max cutting speed with 8,000-10,000 RPM. • Machining aerospace parts

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

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 Machining Software.

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

AEROSPACE PART MACHINING

Boeing B787 wing components machined in Aluminum 11


ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

NVD NICKEL PRODUCTION FACILITY • World’s only commercial Nickel Vapor Deposition facility • Modern, computer controlled plant, built in 2000 • 4 Production chambers, 1 R&D • 24 X 7 operation • 400,000 lbs Ni deposition capacity • 5.7’ X 9.8’ shell size capacity

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

NVD – DEPOSITION PROCESS • Carbon monoxide given off by the reaction is collected and reused in a closed loop system.

• Deposition of Nickel from a vapour creates solid nickel on the outside surface of a heated mandrel, under low pressure in a sealed chamber • The mandrel is a precision, CNC machined duplication (“master”), of the desired shape and surface. It is infinitely re-usable for duplicate nickel shells

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

COMPETITIVE PROCESS COMPARISON Electroformed Nickel Shell

1. 2. 3. 4. 5. 6. 7. 8.

NVD Nickel Shell

0.25mm per 20 hr growth rate Shell thickness is not uniform during growth Inherent residual stresses Cavities made simultaneously from different mandrels Problematic variation - cavity to cavity Replace damaged shell in 12+ weeks Delaminating risk as shells are created in multiple grinding and growth steps Sulfates contamination from electroplating bath = difficult welding + de-lamination risk

1. 2. 3. 4. 5. 6. 7. 8. 9. 14

0.25mm per 1 hr deposition rate Uniform thickness during growth Negligible residual stress Cavities made sequentially from the same mandrel Little variation from cavity to cavity Replace damaged shell in 3 weeks Full shell thickness is deposited in one step with growth being very uniform. 0.999 pure Ni – weldable and no delamination No environmental impact (closed system)


ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

NICKEL VAPOUR DEPOSITION •

The re-usable deposition mandrel is placed in the NVD chamber and heated to approximately 180°C. • Nickel is deposited onto the mandrel at a rate of 0.010in (0.25 mm)/hr of thickness regardless of size • Mandrel must be cleaned and prepared prior to each deposition

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

AUTOMOTIVE INTERIOR NICKEL TOOLING

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

CUSTOMERS – OEM, TIER 1 & TIER 2

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

IN HOUSE MASTERING & PATTERN SHOP In-house Manufacturing of Wrapped Master Models. Extensive Master Model Wrapping Experience with all Interior Components.

In-house Manufacturing and Seam Engraving of Hard Epoxy Master Models.

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

RECENT PROGRAMS

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

FORD C346 – FORD FOCUS WEBER MANUFACTURED WRAPPED MASTER MODEL & THE FINAL EPOXY MASTER MODEL SLUSH TOOLING – (15) 2-CAVITY TOOL SETS (6) SINGLE CAVITY TOOLS (INCLUDING INTEGRATED POWDER SAVERS)

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

JC49 – DODGE JOURNEY – LHD & RHD WEBER MANUFACTURED WRAPPED MASTER MODEL & THE FINAL EPOXY MASTER MODEL

12 LHD TOOLS– 6 RHD TOOLS

SPRAY TOOLING WITH INTEGRATED HEATING SYSTEM

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

CHRYSLER LX (CHRYSLER 300) BOTH LHD & RHD FULL INTERIORS IP, FRONT & REAR DOORS, LEFT & RIGHT CONSOLE PANELS WEBER MANUFACTURED WRAPPED MASTER MODEL & THE FINAL EPOXY MASTER MODEL

IP SLUSH TOOLING – 8 LHD IP TOOLS, 2 RHD IP TOOLS

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

DODGE LD (DODGE CHARGER) IP, FRONT & REAR DOORS, LEFT & RIGHT CONSOLE PANELS WEBER MANUFACTURED WRAPPED MASTER MODEL & THE FINAL EPOXY MASTER MODEL SLUSH TOOLING – 8 LHD TOOLS

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

BMW F25 – BMW X3 - LHD & RHD WEBER MANUFACTURED WRAPPED MASTER MODEL SUBSTRATE & THE FINAL EPOXY MASTER MODELS SLUSH TOOLING – 16 LHD TOOLS – 6 RHD TOOLS

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

HIGH PRESSURE INJECTION MOLDS FOR INTERIORS Nickel shells are mounted into steel cavity shoes and fully supported for injection tooling.

BMW F07 – (BMW 5 SERIES)

Rim Overmold

PUR Overmold 25


ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

NEGATIVE VAC & IMG NICKEL SHELLS FOR INTERIOR FULL CONTROL OF HOLE PATTERN & SPACING PRECISION PLACEMENT OF VACUUM HOLES IN THE VEIN DETAIL ONLY TO MINIMIZE VISIBILITY

.008” VACUUM HOLES EVERY 10mm

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

ADVANTAGES OF NICKEL VAPOUR DEPOSITION FOR NEGATIVE VACUUM AND IMG AUTOMOTIVE TOOLING

ELECTROFORM POROUS NICKEL EXAMPLE

NICKEL VAPOUR DEPOSITION POROUS NICKEL EXAMPLE

VACUUM HOLE PLACEMENT ON NVD NICKEL SHELLS IS DONE PRIOR TO SHELL DEPOSITION WITH FULL CONTROL OVER GRID DENSITY. PLACEMENT OF THE VACUUM HOLES IS IN THE VEIN DETAIL GIVES SUPERIOR IMG SKIN RESULTS. 27


ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

TYPICAL NVD POROUS NICKEL SHELL VIEW OF SHELL SIDE & FRONT NVD POROUS NICKEL SHELLS HAVE THE SAME STRENGTH AS NVD SHELLS WITHOUT VACUUM HOLES

VIEW OF SHELL BACKSIDE 28


CAD Data, Engineering information, and Purchase Order. Design model, mandrel and mold.

NVD TEXTURED NICKEL SHELL PROCESS FLOW INCORPORATING A LEATHER WRAP MASTER MODEL CNC Machine Leather Wrap Model (LWM) Substrate

Substrate CMM Inspection / Approval

Leather Wrapping of Substrate

Cast Epoxy Master Model

Enhance Epoxy Model Seam Lines

Epoxy Model CMM Commission / Inspection

Build Silicone Support Mold

Cast Silicone Negative from Epoxy Master

CNC Machine Mandrel

Cast Silicone onto Mandrel

Nickel Vapour Deposition Process

LWM CMM Inspection / Commission

Shell Stripping and Mold Assembly

Repeat Steps for Multiple Molds/Shells

Cast Silicone Negative from LWM

Mold Inspection and Approval


ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

PRECISION LASER WELDING ON SITE TEXTURE REPAIR SPECIALISTS

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

ADVANTAGES OF NICKEL VAPOUR DEPOSITION… THE NVD PROCESS HAS A NICKEL SHELL DEPOSITION RATE APPROXIMATELY 20 TIMES FASTER THEN ELECTROFORMING

THE NVD PROCESS TYPICALLY PROVIDES A 5-6 WEEK TIMING IMPROVEMENT TO THE FIRST MOLD COMPLETION

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

ADVANTAGES OF NICKEL VAPOUR DEPOSITION…

CONSECUTIVE NVD MOLDS CAN BE DELIVERED IN 2-3 WEEK INTERVALS AFTER THE FIRST MOLD EMERGENCY REPLACEMENT OR CAPACITY NVD MOLDS CAN BE DELIVERED IN 3-4 WEEKS FROM A KICK-OFF

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

AUTOMOTIVE EXTERIOR TOOLING

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

Automotive Exterior - BMW 6 SERIES Cabriolet (RIM Overmold)

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

Volkswagen Eos - Deck-lid Inner and Outer SMC Compression Tools 35


ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

AUTOMOTIVE EXTERIOR – DODGE VIPER Class A Compression Molds Roof outer

Hatch outer Rear Fascia

Rear Quarter panel

Compression & RIM Injection Molds for Dodge 36


ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

DESIGN CAPABILITIES • Extensive CAD/CAM capabilities • 8 workstations running: • UG NX – Primary CAD Software • IDEAS, Catia, Solid Edge and AutoCAD - used for translations • Innovative designers work with customers to contribute to processes and provide tooling solutions. • Our Design Team manages all project information and supports the Machining, Moldmaking and CMM teams. • Strict Engineering Change revision control on all documents and designs to AS9100 standard • Full time in-house IT Department for CAD/CAM/Network support

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

DATA MANAGMENT Data can be received in various formats and ways: •UG NX, IDEAS, Catia, Solid Edge and AutoCAD formats. •Via E-mail, FTP and Odette All data received is logged into our system.

Once the data is logged into the system it is translated into UG NX and a Data Translation Sheet is created.

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

PROGRAM MANAGEMENT • A MS Project master timeline is created for every program. •This master timeline drives various other timelines that specific to each of our manufacturing groups.

• Manufacturing reviews are conducted weekly. • MS Project timeline reports are sent to customers bi-weekly.

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ISO 9001 :www.webermfg.ca 2008 Registered www.webermfg.ca

CONTACTS

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Automotive Interiors