CORPORATION

Precision Engineered Plastics

Cosmo Corporation is a worldwide leader in the design and manufac-ture of precision engineered plastic components. Since 1945, Cosmo has been at the forefront of advanced thermoplastic and thermoset engineering and production. Our experience, technological capabili-ties and commitment to customer service allow us to quickly supply the electrical and electronics industries with the highest quality precision parts at the lowest cost.

Whether your requirement is for a low volume of simple injection molded parts or millions of thin wall components with complex geometries and integrated metal terminations, Cosmo is uniquely positioned to meet your needs and exceed your expectations.

Cosmo Corporation designs, engineers, and manufactures high-precision custom and standard plastic components for the electrical and electronics industries. We specialize in coil forms (bobbins), mounts, headers, encapsulation cases, spacers, knobs and related engineered components.

WELCOME TO COSMO

MAJOR PRODUCTS

PrecisionEngineeredPlastics

While the majority of our production is custom designed and manu-factured for our customers, we also offer over 4,000 standard catalog parts including the world’s largest selection of standard coil bobbins. Our customers can often satisfy their requirements with a standard part and avoid the need for custom tooling. In addition, we maintain extensive inventory enabling us to ship direct from stock without the need to setup a production run. CUSTOMERS & MARKETS

We supply more than 3,500 customers in 40 countries worldwide, including 46 Fortune 500 companies. Our customers represent over 400 industries, and incorporate our components into a diverse range of products. Everything from consumer electronics to industrial motors, telecommunication devices, lighting ballasts, engine controls, and musical instruments all are built around precision plastic components manufactured by Cosmo Corporation.

STANDARD OR CUSTOM

WIDE RANGE OF MOLDING MATERIALSCosmo is capable of molding precision parts in a wide variety of thermoplastic and thermosetting plastics. Our flexibility allows part designers to choose from a larger range of materials and part proper-ties in designing products.

Cosmo employs more than 300 persons in four facilities in the United States, Mexico and China. Our plants include more than 180,000 ft2 dedicated to production and assembly. Cosmo’s corporate head-quarters are located in Cleveland, OH U.S.A.

Plastic MoldingCosmo operates 107 plastic molding machines employing screw injection, thermoset injection, transfer and compression molding methods. Cosmo is capable of molding precision parts in a wide variety of thermoplastic and thermosetting plastics including all engineering grade plastics and many exotic materials. We have the capacity to produce more than 600 million precision plastic compo-nents each year.

FACILITIES AND CAPACITIESSecondary AssemblyIn addition to plastic molding, Cosmo also operates 150 secondary assembly machines to perform a wide range of operations such as metal stamping, metal terminal insertion, lugging, set screw insertion, spring insertion, machining, sonic welding, hot stamping, and painting. Cosmo’s annual assembly capacity exceeds 350 million assemblies.

Tool MakingCosmo Corporation’s facilities also include a 15,000 ft2 tool making facility. Our staff of tool makers operates a full complement of vertical and horizontal mills, surface grinders, die sinking & wire EDM, and CNC machining centers. Cosmo can produce more than 300 new molding tools each year.

Industry Leader

Cosmo operates the most technologically advanced production facilities in the industry. The majority of our production is fully automated to minimize or even eliminate direct labor costs. Our plastic molding and assembly equipment are custom designed and built by our own in-house manufacturing engineering department and are unique to Cosmo. Our machines incorporate advanced robotics, computer controls, LCD diagnostic readouts, and vision monitoring systems to guarantee the highest level of quality, efficiency and speed. Our manufacturing technologies are specifically designed for the high precision products we produce but are flexible enough to adapt to most of our customers’ requirements without lengthy setups or any software programming.

MANUFACTURING TECHNOLOGIES UNIT DIE TOOLINGCosmo has developed a range of proprietary mold base systems uniquely suited for the flexible production of high-precision plastic components. Each of Cosmo’s unit mold bases can accommodate a number of interchangeable cavity inserts. When you require less than a full mold, Cosmo can combine your part tooling with part tooling for other customers, and produce the parts simultaneously in the same mold base. Unit molding provides significant benefits including:

• Significantly reduced tooling lead times• Lower tooling costs• Lower part prices by sharing molding costs• Production flexibility• Faster tooling setup times with all tooling changes performed at

the parting line

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Innovation

ISO9001 QUALITYAll of our facilities are ISO 9001:2000 registered. Cosmo achieved ISO 9002 certification in 1999, and ISO 9001:2000 certification in 2002. Cosmo is registered under certificate number 21651-1.

UL RECOGNIZED MOLDERUnderwriters Laboratories requires that all plastic coil forms and certain other plastic components used in electrical devices must comply with UL standards and must be made by a Recognized Molder (QMMY2). Cosmo has been a UL Recognized Plastics Molder (QMMY2) under number E136933 since 1990.

CUSTOM ENGINEERING & DESIGN SERVICESCosmo’s product engineering department is dedicated to working with customers in the design and development of new or redesigned parts. Cosmo’s design services are offered at no cost and include:

• Full part print layout on 3D CAD.• Dimensional analysis based upon shrinkage for proper fit of

mating parts.• Part design that optimally meets your needs, requires the least

expensive tooling, and creates a part highly suitable for produc-tion or assembly.

• Material selection assistance.• Analysis of regulatory requirements.• Sophisticated CAD/CAM modeling to simulate the results of the

mold design, including material flow and mold cooling.• Part standardization analysis.

LOGISTICS SUPPORT SERVICESCosmo offers a wide range of logistics support services including:

• Cosmo managed inventory - Just-in-time, KanBan, forecast planning

• Consignment stock programs• Automatic order tracking, acknowledgements and notices via

email, fax, or on-demand reporting• Custom bar coding on shipments• Returnable packaging programs• Standard or customized electronic data interchange and online

collaboration

QUICK-SHIP PROGRAMIn order to serve our customers better, Cosmo maintains a Quick-Ship Program for selected catalog items. All Quick-Ship parts are stocked and available for next day delivery. This program includes the most popular parts in our catalog in selected materials.

EARLY VENDOR INVOLVEMENT PROGRAM (EVI)Cosmo’s EVI program brings Cosmo design engineers in at the beginning of the development process, and helps avoid costly rework. EVI also offers the flexibility of electronic sketch, drawing and document exchange to reduce the design phase from months to days.

QMMY2

60 YEARS OF EXPERIENCEIn 2005 Cosmo Corporation celebrated its 60th anniversary. Since 1945, Cosmo has produced more than 15,000 plastic molding tools and close to 5 billion precision plastic components. Over the years we have continued to grow by focusing on our customers, pursuing technological innovation, and hard work. We are looking forward to another 60 years of growth and success.

As part of an ongoing global expansion, Cosmo is pleased to announce the opening of our new manufacturing and assembly plant in Tianjin, China. Conveniently located two hours southeast of Beijing, in the Tianjin Economic Development Area (TEDA), the facility spans 86,000 ft2, and showcases our latest generation molding and assembly technologies. The plant’s molding operations feature fully-automated, all-electric molding presses with custom designed robotics. Secondary operations include insertion of flat-stamped and wire terminals, painting, and automatic, semi-automat-ic, and manual assembly. The plant also includes a 15,000 ft2 toolshop featuring CNC milling, EDM, and precision grinding machin-ery. With an initial investment of over US$12 million, Cosmo’s new wholly-owned Tianjin facility provides expanded support for our customers in East Asia and export markets around the world.

Cosmo’s Tianjin operations were designed for full integration with our North America operations. With uniform manufacturing methods and mirrored equipment, tooling currently running in Cosmo’s US plants can be air shipped and running in our Tianjin plant in less than 96 hours, at the same level of quality and precision. In addition, Cos-mo’s Tianjin operations are linked to Cosmo’s central computer system to provide complete visibility to customer production world-wide. No matter where your parts are being produced, you can contact Cosmo’s customer service departments in the US or China and get instant feedback on the status of your order or engineering questions. So whether you need immediate delivery of parts to Shanghai, China, or engineering assistance in Peoria, IL, Cosmo is committed to meeting your needs with uniformly superior quality.We look forward to working with you.

TIANJIN, CHINA PLANT

可兹莫公司

60 Years

PLASTRON ACQUISITIONIn February of 2006 Cosmo extended its reach along the U.S.-Mexico border with the acquisition of Plastron, a manufacturer of coil bobbins and precision plastic components. The integration of Plastron’s molding and assembly facilities in Pharr, Texas and Reynosa, Mexico with the rest of Cosmo’s operations offers benefits to both Cosmo and Plastron customers through increased economies of scale and tangible manufacturing synergies.

USA30201 Aurora RoadCleveland, OH 44139 USATel: (+1) 440-498-7500Fax: (+1) 440-498-7515www.cosmocorp.com

China69 Tenth AvenueTianjin Economic Development Area Tianjin, 300457 P.R. ChinaTel: (+86) 22-5988-6500Fax: (+86) 22-5988-6525www.cosmocorp.com