1STC Molds 2013may

STC - Molds
Strategic Tooling Center, Greensboro, NC
05/16/13 DAC
Capabilities of STC Molds
• Design – CAD/CAE
• Project management for entire new tooling programs
• Collaboration with STC Dies
• Construction – Conventional and Micro-machining
• Offshore builds with in-house fitting, assembly and conditioning
for lowest cost tooling
• Conditioning to 1st article production release
• Quick Turn Mold Platforms
• Sampling/Pre-Production
• Inspection
• Quoting
Information is Tyco Electronics Confidential & Proprietary page 2

Do Not Reproduce or Distribute
STC Services
• Design and build and Condition New Molds to Customer

approval. (Production, Prototype)
– Insert Molding, Reel to Reel, Loose Piece
– Overmolds; cables, other molded parts, etc.
– Hot Runner Molds, Direct gate
• Rapid Response Design and Build (more later in presentation)

• Refurbish existing tools that are in need of repair (Criminal
Tools)
• Spare Tooling for Molds, Dies, Assembly Equipment, Etc.
Information is Tyco Electronics Confidential & Proprietary

STC Services cont.
• Mold Flow / Warp / Cool Analysis
• Design & build, product Extensions, Additions, ECN’s to Existing

mold
• Design Only (Give back to BU Engineer)

Staffing = 48 Associates = Over 900 years experience in
Mold/Plastics industry. Including:
• 12 seasoned mold designers using ProE and ACAD w/

6 trained in Moldflow analysis
• 25 experienced toolmakers
• 5 project engineers to manage mold build programs
• 5 MasterMolder trained processors
• 4 Micro-machining technicians

STC Design & Engineering Capabilities
• CAD =17 seats of ProE/Autocad

• CAE = 6 seats of Moldflow Analysis for “right the 1st
time”
• Art to Part – 3D design to mold steel to plastic parts
• Early involvement with Product Development
• Experimental tooling platforms for Advanced
Manufacturing Technology
• Scientific Injection Molding – Engineering
Benchmarks/53P
• EDart Process Control Technology – In mold sensors
and close loop molding processes

STC Mold Construction Equipment Highlights
• 12 Surface Grinders, 1 Wet Grinder

• 3 CNC Mills
• 1 Charmilles 40, 3 Charmilles 20 Plunge EDM’s
• Twin wire Charmille EDMS 2050 & 6050
• Cuts unattended up to 64 hours straight. No labor!
• Mikron HSM 500 High Speed CNC Mill

• Cuts hardened steel and electrodes
• Micro-Machining Laboratory
• Climate controlled Micro Machining and metrology lab equipped with all
machinery required for sub-micron level tolerance parts

MICRO - MOLDS
Micro Manufacturing
• What is Micro Manufacturing?
Build, condition and inspect Micro Molds and Parts down to the sub micron
level.
• Micro Molding?
Generally, Micro molding can be defined as molding plastic parts that contain
the following attributes;
Fractions of a plastic pellet or weighing fractions of a gram
Having wall thickness of less than .005”(0.127mm)
Having tolerances of .0001” to .0002”(0.0025 to .0050mm)
Having geometry seen only by use of a microscope

Micro vs. Conventional Manufacturing
• Micro Manufacturing • Conventional Manufacturing

Unable to achieve the level of detail or finishes
Extremely small features with crisp detail and high
required for many Micro applications.
quality finishes
Unable to consistently meet the required tolerances
Tighter tolerances (micron and sub micron level)
Notice the finish and level of detail present for Micro Applications
.010 [.0004] step feature on part Notice the finish and lack of detail

STC Micro Molding “wins”
• Most 5G Ferrule
• Alignment Mechanism, In Ferrule
• 48 Position MT Ferrule
• Micro Features on standard product
• 1 Second Molding DOE

48 Position MT Ferrule
• Notable product requirements
.125 [.0049] dia. fiber holes on .250 [.0098]
centerlines
• Fiber hole plastic part tolerance requirement

.001 [.00004] requirement on dia
.003 [.0011] tolerance requirement on positional
accuracy .
• Keys to success (Sarix, Rollomatic, Makino

UPN Wire EDM)
100 [.0039] start holes 8.52 [.335] required (85
to 1 aspect ratio)
Manufacture small core pins

Alignment Mechanism, In Ferrule
• Notable Product requirements

Part Weight .012 grams [.0004] ounces
.2 RA Finish required on standing “V” area.
.001 [.0004] max waviness required for “V” groove
General product print tolerances of .01[.0004] to
.02[.0008}
• Keys to success (Single Point Diamond Turning
Machine, Sarix)
Proper distance relationship from ball seat to “V”
groove
Meet “V” groove surface and waviness requirement
Ball Seat
“V” groove

Lensed Ferrule Most 5K
• Notable Product requirements
Body diameter
Aspheric lens prescription
Optical fiber insertion and termination
• Plastic part tolerance requirement

.003 [.00011] requirement on positioning area of
main body.
.0025 [.0001] tolerance requirement on positional
accuracy of Optic fiber.
Ra 0.065 Optical surface requirement for lens and
fiber termination surface.
• Keys to Success (Single Point Diamond

Turning machine, Sarix, Makino UPN Wire,
Makino IQ300 Micro Mill)
Cut aspheric lens to proper lens prescription
Meet “V” groove surface and waviness
requirement
Meet spec on Optical fiber “capture” area

Micro Features on standard product (Molds and Dies)
“Eye of the Needle”

1 SECOND MOLDING DOE.
STC was invited to participate in a DOE with the Technology Group to develop a mold to run a cycle as close to 1
second as possible. 2 “B” sides were constructed to utilize the molding press’ rotary option and to remove the ejection
portion of the cycle from the process. Conformal cooling along with highly thermally conductive materials were also
utilized in the mold construction to reduce cycle time.

Equipment list (Current and proposed)
• Sarix Linear EDM machine (Greensboro in use)

• Moore Nanotechnology SPDT machine (Greensboro trained)
• Makino Wire EDM machine (CER approved 9/23/13)
• Climate Controlled MM lab (approved ECD 12/12/13)
• Mitutoyo UMAP Metrology device (ordered ECD march 2014)
• 3R System fixture/pallet system (CER approved 9/23/13)
• Gage Blocks, Sub Micron Indicators (CER approved 9/23/13)
• Laptop Computers w Docking stations (CER approved)
• Benches, tables, Surface plates (CER approved)
• Battenfeld Microsystems 50 Molding Press (In Harrisburg)
• Yasda 5 Axis machining center (CER approved 9/23/13)
• Alicona Infinite focus (metrology) (Greensboro in use)
• Rollomatic Shapesmart NP5 5 Axis Pinch Grinder (CER
submitted)
• interferometer white light (Metrology of lenses) CER submitted

1728 sq ft. Climate Controlled MM lab
Requirements;
• 1,440 sq. ft.
manufacturing
• 288 sq. ft. metrology
• Modular design
(Portable)
• 44 20° C +/-.5°C Temp.
Control
• 44% +/-5% Relative
Humidity
• Lab temp. monitored
and controlled in 3
locations.

Sarix Linear EDM machine
• Linear Rod EDM process
• Fine hole drilling capable. (100
micron diameter 16mm deep.)
• Ultrafine EDM resolution

Moore Nanotechnology SPDT Machine
• For Lens manufacturing
• Micro milling package for aspheric lens cutting.
• Can be used as a 4 axis mill
• .01 nanometer programming resolution
• 34 Pico meter linear scale feedback system
• Cut lens, V grooves, Ruling, Light Micro Milling

Makino UPN Wire EDM Machine
• Wire diameter from 0.02 [.0008] to 0.1 [.004]
• “Turn and burn” capable
• Work indexing accuracy +/- 2 seconds
• .0005 mm Positioning and Repeatability
Accuracy (at 20±1°C thermostatic room)

Keyence 3D Laser Scanning Microscope
• A Microscope, SEM, and roughness gauge in
a single unit
• Non Contact 3D surface measurements
• Image stitching
• 87 degree angle of detection (diffused)
Dust particles

Mitutoyo UMAP Metrology device
• Multi-Sensor Device; capable of optical (non-contact)
and tactile (contact) measurement.
• Scale Resolution of .01micron , accuracy to .25 micron

over a 400x400x250 measuring envelope.
• Interchangeable objectives and stylus increase flexibility.
• System traceability to ISO specifications.
• Fully capable of 3-D geometric analysis of diameters, slots
and wall dimensions (internal and external)
Image based
analysis and
Optical Tactile stitching

System 3R Macro Nano fixture/pallet system
• Sub-Micron Palletizing System for

Micro- and Ultra precision Machining
• Studies at Fraunhofer IPT show an
indexing accuracy of better than
.0005mm.
• This accuracy was achieved even
though more than 1 machine was
involved in production.

ROLLOMATIC SHAPESMART NP5 5 AXIS PRECISION
CYLINDRICAL PINCH/PEEL GRINDING MACHINE
• For round core pins

• Range from .025[.001] to
20mm [.787]
• Size control within .0005
[.00002]
• Mirror surface finish
• Tool run out concentricity
with.001 [.0004]
• Accurate shape control

Yasda 5 Axis Machining Center
• State-of-the-art linear motor

design,
• 0.005-micron scale feedback
• Measure tool lengths to sub-
micron levels of accuracy and
repeatability,

Battenfeld Microsystems 50 Molding Press
• Unilog B4 Control System

• Dose and Plunger injection unit
• Three-axes robot system which enables
a careful handling of micro parts.

Conventional Molds
16 Cavity SMT Housing

4 Cavity Seal Cover

Hot Runner Molds
8 Cavity Outer Flange

Hot Runner Molds
8 Cavity Wire Dress

Insert Molds or “Over”molds
4 Cavity Strada Chicklet

Pre-mold
Post-mold


Face Mounted Modules for in press changeovers
Product
Stationary
Side module
Ejection
Side module
Complete
module
Information is Tyco Electronics Confidential & Proprietary page 36

STC – Optimized Vent Designs
Allows reduced injection

pressures, improved mold
maintenance, eliminate
gas burns:
•Venting Analysis
•Porcerax II inserts

Vent Analysis: Determine optimum vent requirements in molds
based on materials data, tooling and shot volumes

•Divider Slide Title
Core Pin Manufacturing
Core pin manufacturing for Strada Mesa Receptacle
mold
• 160 Core Pins Manufactured in 2 weeks
• Made In House STC Mold Shop Greensboro NC.
• Equipment used
– 2050 TW Charmille Wire EDM machine (Twin Wire)
– Mikron High speed CNC hard cutting Milling machine
– Charmille Roboform 20 CNC plunge EDM machine
– Okomoto 6-12 Surface Grinder
– Erowa Tooling

Core pin for Strada Mesa Receptacle Mold
80 Required

Core pin For Strada Mesa Receptacle Mold
80 Required (Pin form rotated 90 degrees)

Job starts with a block of steel 2” x 2” x 4” high. Block is wired in both directions.
Charmille Generator ensure straightness of core pins

Electrode Manufacturing: (4 styles) 4 different blocks similar to the one shown here. These electrodes need to
be made on our high speed mill. It as accuracies of .0001”/.0002” (.0025/.005mm) we need these accuracies in
order to be able to EDM 80 core pins at a time.

Core pins shown with Pilots .0100” (.25mm) dia. EDM’d on top, .008” (.25mm) slot EDM’d into
side of core pin (81 pins EDM’d at the same time)

Core Pin Pricing (Suppliers quote) STC actual
Item # $’s per pin Quantity Lot Price Supplier Notes Lead Time
29-393975/76 $41 160 $6,560 STC w/programming 2 weeks
29-393975/76 $27.50 160 $4,400 STC No/programming 2 weeks
29-393975/76 $110 160 $17,600 Edaran 7 weeks
29-393975/76 $115 160 $18,400 Quality 4 weeks
29-393975/76 $122 160 $19,520 Goudie 4 weeks
29-393975/76 $141 160 $22,560 Executool 4 weeks
29-393975/76 $159 160 $25,540 Maloney 5 weeks
29-393975/76 $319 160 $51,040 Tool-all 8 weeks
29-393975/76 $350 160 $56,000 Ace Tool 6 weeks

Core Pins Manufactured for 2 MM Z-pak Receptacle
mold
• 150 Core Pins Manufactured in 2 weeks
• Made In House STC Mold Shop Greensboro NC.
• Equipment used
– 2050 TW Charmille Wire EDM machine (Twin Wire)
– Mikron High speed CNC hard cutting Milling machine
– Charmille Roboform 20 CNC plunge EDM machine
– Okomoto 6-12 Surface Grinder
– Erowa Tooling

Wire EDM Innovation
• Wire profile cut in one direction (Slide 1)

• Wire Profile cut other direction (Slide 2)
• Each block of steel will produce 75 core pins

Core pins after being wire EDM’d both directions

Electrodes for Pilots for interlocking core pins, 300
pilots on one electrode EDM’ing 75 core pins at once.

Core Pin Pricing (Suppliers quote) STC actual
Item # $’s per pin Quantity Lot Price Supplier Notes Lead Time
29-787294 $16.80 150 $1,260 STC w/programming 2 weeks
29-787294 $9.60 150 $720 STC No programming 2 weeks
29-787294 $120 150 $9,000 Ace No Chrome 4 weeks
29-787294 $67 150 $5,025 PGS No polish/chrome 5 weeks
29-787294 $58 150 $4,350 Edaran 6 weeks
29-787294 $52 150 $3,900 LNE 4.5 weeks
29-787294 $51 150 $3,825 Maloney 4 weeks
29-787294 $38 150 $2,850 Executool 3 weeks
29-787294 $18 150 $1,350 Vico No chrome 6 weeks

CAE – MOLDFLOW ANALYSIS
page 55
MOLDFLOW - Filling and warp analysis
Influence of :
- Injection point location
- Geometric changes
- Wall thickness

Product-features : Premium Housing 38 pos

Injection point location :

A. Flatness through bushing-top :
(ref.-plane through points X1, X2, X3)
Center gated : Front connector 3 points gated :

dZ[mm]: dZ[mm]:
+0.23 -0.31
2 1
Wall coil side gated : Front connector 2 points gated :

dZ[mm]: dZ[mm]:
+0.10 -0.22
4 3

B. Deformation connectorwalls :
Front connector 3 points

2 3
Center

1 4
Wall coil side

C.2 Warpage Laserweld, Y-direction :

2 4
Center
ÅY
ÅY

1 3
Wall coil side
ÅY
ÅY
D. Bending connector region compared
to coil area :

Center
2 3

Wall coil side
1 4

Comparison Table : Best Gate Locations
Center Wall coil Front Front

side connector connector
3 points 2 points
A. Flatness through bushing-top. 2 4 1 3

B. Deformation connectorwalls. 2 1 3 4
C.1 Warpage Laserweld, X-dir. 1 3 4 2
C.2 Warpage Laserweld, Y-dir. 2 1 4 3
C.3 Flatness Laserweld, Z-dir. 2 1 3 4
D. Bending connector region 2 1 3 4
compared to coil area.
E. Bushing position compared to 1 2 3 4
drawing reference.
Total 12 13 21 24

MOLDFLOW – Latch Beam Analysis

MOLDFLOW – Latch Beam Analysis

CAE - RIGHT THE FIRST TIME USING MOLDFLOW TOOLS
Mold Temperature
Combiner Box
Part Temperature
Water-lines and Baffles

CAE - RIGHT THE FIRST TIME USING MOLDFLOW TOOLS
Differentional Cooling
Deflection

Conformal Cooling
STC – Conformal Cooling Applications
Cooling lines machined in

blocks then brazed together.
Allowing maximum water flow
to cavity.

Main Core Block

STC Quick Turn Molds
Rapid Response Mold Tooling Platforms
•Design directly using Pro/E Product Models
• No “Drawings” required from Product Engineering
•Designer creates Tooling Models for all Mold

Components
•Minimal “Detail Drawings” required from Mold Design
•Shop builds Tooling directly from Tooling Models
•Majority of machines in Tool shop CNC capable

Rapid Response Mold Tooling Platforms
• STC has created 2 mold building platforms for Rapid

response mold building.
• The purpose is to reduce TTM
• Conditioned mold models can also be used in

decreasing TTV.
• Focus is on designing, building and sampling a mold

within a 1 to 3 week time frame

Rapid Response Base Small Unit: A-Side

Rapid Response Base Small Unit: B-Side

Rapid Response Mold Tooling
Blank inserts “On the Shelf” Made in Qty.

INTERCHANGEABLE CAVITY ASSEMBLY

Rapid Response Base Larger Units: B-Side

Rapid Response Base Larger Units: A-Side
77 x 100 mm workable
area for the 3 slide pocket
(3.031” x 3.937”)
100 x 122 mm workable

area for no slide pocket
(3.937” x 4.803”)

Quick Turn ITB Connector Program
Design + Build + Sample all (3) Tools in Total = 15 Days

Nevalo Program
Designed and built 2 parts 2 weeks - 3rd part 3 weeks

Rapid Response Tooling - “Quick Turn”- ITB Connector
Program
HEADER HOUSING - P/N 2106768
Design, Build & Sample = 8 Days

Rapid Response Tooling- “Quick Turn”- ITB Connector
Program
PLUG HOUSING - P/N 2106771

Quick Turn Process – Part model to plastic parts

Quick Turn Quattro Receptacle
Design & Build 2 weeks (Over Holidays) $9,000

SSF BASE AND SLIDER – pn2106630 & 34
Design, Build, and Sample in 2 weeks

PN 2106647- SSF WTB PLUG
Design, Build & Sample in 12 Days

NEXT
Future Plans
• Moving operation to 3900 Reidsville Road location

• Setting up complete Micro Lab at RR
• Adding Micro Molding room next to new Micro Lab
• New location will provide facilities for Master Molder
Training
• New location will provide facility for complete work
cell development
• Conditioning of entire work cell and then transfer to
production

Contacts in STC Molding
• Dave Cranmer -- Operations manager

336-544-1326 dacranme@te.com
• Paul Simpson – Engineering Manager

336-544-1308 rpsimpso@te.com


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STC - Molds

Strategic Tooling Center, Greensboro, NC

Information is Tyco Electronics Confidential & Proprietary page 2

• Design and build and Condition New Molds to Customer

• Rapid Response Design and Build (more later in presentation)

Information is Tyco Electronics Confidential & Proprietary

• Mold Flow / Warp / Cool Analysis

• Design & build, product Extensions, Additions, ECN’s to Existing

• Design Only (Give back to BU Engineer)

Information is Tyco Electronics Confidential & Proprietary

• 12 seasoned mold designers using ProE and ACAD w/

• 5 project engineers to manage mold build programs

• 5 MasterMolder trained processors

Information is Tyco Electronics Confidential & Proprietary

• CAD =17 seats of ProE/Autocad

Information is Tyco Electronics Confidential & Proprietary

• 12 Surface Grinders, 1 Wet Grinder

• Cuts unattended up to 64 hours straight. No labor!

• Mikron HSM 500 High Speed CNC Mill

Information is Tyco Electronics Confidential & Proprietary

Information is Tyco Electronics Confidential & Proprietary

• Micro Manufacturing • Conventional Manufacturing

Information is Tyco Electronics Confidential & Proprietary

• Alignment Mechanism, In Ferrule

• Micro Features on standard product

• 1 Second Molding DOE

Information is Tyco Electronics Confidential & Proprietary

• Fiber hole plastic part tolerance requirement

• Keys to success (Sarix, Rollomatic, Makino

Information is Tyco Electronics Confidential & Proprietary

• Notable Product requirements

Information is Tyco Electronics Confidential & Proprietary

• Plastic part tolerance requirement

• Keys to Success (Single Point Diamond

Information is Tyco Electronics Confidential & Proprietary

Information is Tyco Electronics Confidential & Proprietary

Information is Tyco Electronics Confidential & Proprietary

• Sarix Linear EDM machine (Greensboro in use)

Information is Tyco Electronics Confidential & Proprietary

• 288 sq. ft. metrology

• 44 20° C +/-.5°C Temp.

• 44% +/-5% Relative

• Lab temp. monitored

Information is Tyco Electronics Confidential & Proprietary

Information is Tyco Electronics Confidential & Proprietary

• For Lens manufacturing

• Micro milling package for aspheric lens cutting.

• Can be used as a 4 axis mill

• .01 nanometer programming resolution

• 34 Pico meter linear scale feedback system

• Cut lens, V grooves, Ruling, Light Micro Milling

Information is Tyco Electronics Confidential & Proprietary

• Wire diameter from 0.02 [.0008] to 0.1 [.004]

• “Turn and burn” capable

• Work indexing accuracy +/- 2 seconds

• .0005 mm Positioning and Repeatability

Accuracy (at 20±1°C thermostatic room)