Weber Manufacturing Technologies is a leading manufacturer of precision tooling for the aerospace, automotive, and building industries located in Midland, Ontario, Canada. It has over 140 employees and 135,000 square feet of facilities. Weber offers tooling in materials like steel, invar, aluminum, and nickel using processes like CNC machining and nickel vapor deposition. It has a wide range of customers in composites and precision machining.
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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)
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ISO 9001:2000 REGISTERED
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TOOLING PACKAGES: Example - BOEING 787
300 tools = Lay-up Mold’s, Trim & Drill Fixture’s and Hot Drape Form Tools
(Invar, REN Board and Aluminum)
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• 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
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• 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
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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
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Bell 429
Completed nose
cone tool and
frame
+120 other tools
AEROSPACE
APPLICATIONS
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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
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LAY-UP TOOLING
• Weber is a Boeing Approved Tool Supplier
• Nickel tools for 787-8 leading edge of vertical stabilizer
PROCESS APPLICATIONS
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LAY-UP TOOLING
• Multi Tool Program of Nickel Lay up tools for Sikorsky Black Hawk UH60M
PROCESS APPLICATIONS
• Aluminum collapsible
APU duct tooling
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NVD Nickel Lay up tool for high temp
Polyimides >300 Celsius (600F process)
Nickel Shell Application
PROCESS APPLICATIONS
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•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
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• Trim and drill fixtures
• Production assembly
fixtures for windscreen
• Welded and machined 407 bonding fixture
• ‘Soft’ Master models
FIXTURES and MODELS
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MACHINING FIXTURES
220 Inches
Aerospace Machining Fixture With Vacuum
Holding
A2C2 Double Vane
Machine Fixture
A2C2 Doublet Bond
Fixture
A2C2 Single Vane
Machine Fixture
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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
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•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
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OUT OF AUTOCLAVE
See separate presentation
ISO 9001 : 2000 Registered
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ISO 9001 : 2000 Registered
www.webermfg.ca
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• 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
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• World’s 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
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- 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
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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) -> ¼” 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
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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
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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)
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• 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
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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.
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CERTIFICATIONS
• Quality standard is ISO 9001:2008
• Registered with Canadian Controlled
Goods Program - Registration No. 22921
• CWB W47.1, W59 Welding certificates
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• 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
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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
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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
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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.
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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.
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• 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
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•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
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In House Handwork
Handwork Department Deals With Steel,
Aluminum, Nickel, & Invar Molds
Weber’s Handwork and Polishing
Department can handle all types of mold
finishes including Class A and High
Diamond Polish
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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
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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.
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16566 Highway 12
P.O. Box 399
Midland, ON L4R 4L1 CANADA
Direct
Mobile:
Email:
(705) 527-2976
(705) 527-2123
rob.sheppard@webermfg.ca
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
tom@helle-t.de
HEAD OFFICE
Tom Schmitz
Business Manager
(705) 527-2956
(705) 527-2154
tom schmitz@webermfg.ca
Robert Sheppard
Vice President
Greg Leidig
U.S. Sales Agent
Mobile:
Email:
(419) 481-3645
Greg.leidig@webermfg.ca
UNITED STATES of AMERICA
