Understanding the Process
Yes , it is "Insert Molding" - that is the simple part. , anyone can put a piece of screen in a mold . The Cost savings & Shielding Effectiveness are part of our Product Development Program. It is our understanding and knowledge of all facets concerning effective emi shielding , molding / materials and mold design. We know how to address all of the features your shielded enclosures require - including production cost.
Molding History Low production Cost.
Beyond the 35 years in the plastic industry from Tool Engineer , Chief Engineer , to National Product Manager with the Automotive and Electronics Industry , we have over 20,000 press hours developing every possible detail related to Producing a Cost Effective Shielded Product Out of the mold.

For molders who use labor at the press. We can engineer a system that will fit into their costing.

We can engineer systems from under $10,000. to a high volume "Lights Out "
Program Examples

Molder Example , ( Large international Molding Co.) :

Manager of Engineering said ; " It cannot be done " the cycle time will to long , at least 55 seconds , the reject rate will be to high , the customer cannot afford it . He than added , the system cost would exceed $380,000. , he had his staff develop a quote to prove it.

BTI:

Working with the Customer , we developed the correct design for the enclosure , built the mold and system and delivered it to the molder.

After one day for set-up , they were molding Shielded Parts.

With a 32 second cycle . The system cost for a total automatic System "Lights Out " , capable of feeding 2 molding machines for a yearly volume of 2,500,000 parts , was $89,000.

After 8 hours of production the Engineering Manager reported , 0 rejects , and they reduced the cycle to 28 seconds , he than Congratulated the Team.

Customer ( End User) Audio Enclosure.

For 3 years their Corp. Engineering staff rejected the process based on : Sheet Metal is the only way , Plastic won't work , period . What was very frustrating , their manufacturing engineering and production as well as the EMC group all supported it.

It was not until their was a Corporate Mandate sent out - "We Must Reduce Cost " we finally received the approval , and they Won.

If they had started 2 years earlier they would have saved over $10,500,000 a year.

 Others have tried it.

Since we first display parts , and after most of the seminars we have provided , companies have attempted to mold parts at some level . This is no surprise to us ,

However , what is a surprise is , after they fail to produce a good part , they claim , the process can't be done., and than state all of the problems they had.

As we have stated many times , Inserting the Mesh is the simple Part - making a good part requires an understanding the details of each component of the process:

which Includes :

Mesh material , (size , type , process)

Part Design ( Emc requirements , function )

Mold design. ( Parts , Emc and process )

Injection Molding Process ( EMC , part , process )

Overall Costing & Manufacturing.
No of Steps
Operations After Molding
 Gridshield Vacuum/Met
1 Inspect / /ship to customer x
2 Inspect & Pack ship to surface Coat x
3 Un-pack x
4 Rack x
5 Clean x
6 Coat x
7 Bake x
8 Un-load x
9 Un-rack x
10 Inspect x
11 Pack/ship return to x
12

Cell Unit - all work is completed at the Press - A fully Shielded part right out of the press.
This unit can feed 2 molding machines - can produce 2,500,000 units per year .