Let us show youthe wayto a better component.

Helping you achievethe best possible component

Every time you design a component, you set more ambitiousobjectives: smaller size, enhanced performance, increasedreliability, and improved manufacturability at lower cost.

Microplastics provides the way to reach those objectives with uniqueinsert molding solutions that help you achieve even more than youthought possible.

How do we do it? With unrivaled insert molding expertise,state-of-the-art equipment, a highly efficient project process andcomprehensive support services.

We’ve developed innovative insert molding solutions for companies ina wide range of industries, including automotive, electronics, telecom-munications, appliance, computer, and medical. Past projects have included:

• Switches and relays • Connectors• Lighting • Timers, sensors, and alarms• Filters • Disk and tape drive components

Our unique in-house capabilitiesAt Microplastics, we control the entire insert molding productionprocess under one roof, which promotes superior quality and timesavings. Our complete services include:

EngineeringOur highly knowledgeable team of insert molding design engineeringspecialists are ready to consult with you, making recommendationsfor optimizing your component’s performance, manufacturability, andcost. The team uses advanced 3-D and CAD tools to facilitate designs.

ToolingAt Microplastics, every mold is built in-houseby world class tooling professionals. We buildyour mold, maintain it, and guarantee it forthe life of your program.

MoldingOur molding group can produce extremely

complex components in high volume. We can employeither skilled personnel or robots for loadinginserts into the molds and for part removal.

AssemblyIn addition to molding, we provide complete assembly operations.Assembly includes a variety of secondary processes, includingmicrosoldering and applying adhesives.

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The Microplastics Process™

Achieve your most demanding design goals with the MicroplasticsProcess™. This proprietary project process helps you maximizequality while minimizing time and costs on component projects,from feasibility evaluations through final testing.

ResearchTo determine the best manufacturing solution for you,we will evaluate materials, construct experimental tooling,and use Design of Experiments (DOE) methods to verifydesign theory conclusions.

DevelopmentOur custom-designed quotation system, using ActivityBased Costing, produces accurate prices for specificdesigns and helps identify the best configuration.It can provide quotations for various combinationsof material, processes, and tooling, and helps directproduct design development towards changes thatwill have the greatest impact on total cost.

PrototypesMicroplastics builds prototypes as part of a total program,not as an end in itself. To ensure that our prototypes accuratelyreflect the final production process, we construct prototype molddetails of pre-hardened or hardened tool steel, the same materialused in production molds.

Project SupportA Microplastics Project Manager leads your entire productionproject from beginning to end using computer-networked check-lists. Representatives from sales, engineering, QA, materials,purchasing and manufacturing form a team that will work withyou throughout your project.

Quality AssuranceAs an ISO/QS 9000 certified supplier, we prevent potentialproblems by using such tools as Advanced Quality Planning(AQP), Design Failure Mode Effects Analysis (DFMEA), andProcess Design Failure Mode Effects Analysis (PFMEA).We operate at or near zero ppm defects.

The benefits of insert moldingInsert molding is a process by which metal stampings, bushings,electromechanical components, filtration materials, and otherdiscrete parts are combined into a single component throughthe injection of thermoplastic around the carefully placedparts (inserts).

A highly efficient alternative to assembling discrete parts withconnectors, solder, and adhesives, insert molding offers manyoutstanding benefits:

Reduced assembly and labor costsThe insert molding process greatly minimizes assembly andlabor by allowing numerous components to be combined into asingle component, joined by thermoplastic. For example, a singlestamping can be overmolded, then perforated to create multiplecircuit paths.

Reduced size and weightBy eliminating fasteners and connectors,and by combining the physical strengthof resin and metal inserts, insertmolding yields smaller andlighter components.

Increased reliability During insert molding, moltenthermoplastic resin flows in andaround the parts (inserts), filling voidsand securing parts to prevent looseningor improper terminations. The thermoplas-tic resin also provides improved resistance toshock and vibration.

Increased design flexibilityInsert molding allows virtually unlimited design configurations.For example, in creating a 3D circuit board, overmolding permitscircuitry to move freely through the part, from inside to outside,up walls, down in holes—and the plastic ties it all together.

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Call your Microplastics representative today at (630) 513-2900.

406 38th AvenueSt. Charles, IL 60174Phone: (630) 513-2900Fax: (630) 513-2901www.microplasticsinc.com

QS9000 Registered

© 2001 Microplastics, Inc. 10M