Plastic Moulding Plastic Moulding Optical Moulding Technical Moulding Formed-in-Place Gasketing Designed and Manufactured in the UK Edition 2 01420 470400 www.fernhoward.com/plastic-moulding
Fern-Howard Plastic Moulding Years of experience, background in lighting & optics Injection moulders for over 27 years, few companies have Fern- Howards breadth of experience. Capable of moulding simple components through to large and complex optical elements requiring injection-compression, we can undertake every step of the injection moulding process - from component and tool design and build, through compound selection and development to final hand finishing. Our own Lighting Range Much more than just injection moulders we produce in excess of 2 million components each year for use in our own award-winning lighting ranges. That means we understand quite why accuracy is so important and why delivery times matter. It is why, when supplying customers from across the world from our modern, 24-hour, UK-based plant we can take pride in the quality and efficiency of our work and the skills of our workforce. Page 2 Tel: +44 (0)1420 470400 Email: plasticmoulding@fernhoward.com Visit: www.fernhoward.com/plastic-moulding
Plastic Moulding Able to undertake large and complex or small jobs Our twenty injection moulding machines range from 35 tonnes to 1,000 tonnes clamp force. This means we are able to undertake large and complex jobs with confidence and small jobs with exceptional efficiency - processing a range of engineering polymers to produce components with a shot weight of a few grams to 3.5kg. Our background in commercial lighting specifically the moulding of optically pure light guides for LED based luminaires and the skills learned in this demanding area means our quality control and consistency levels are high. We manufacture components for the electronics industry, for the medical industry, and for companies large and small. Indeed for anyone who demands cost-effective high standards, delivered reliably. Precision injection moulding Optical moulding Technical moulding High and low volume Formed-in-place Gasketing Tel: +44 (0)1420 470400 Email: plasticmoulding@fernhoward.com Visit: www.fernhoward.com/plastic-moulding Page 3
Optical Moulding Quality and optical precision Optical moulding is challenging, and tool finish critical, for even small imperfections or deviations will be magnified, harming end product performance. We have extensive experience within the optical industry, forming strong partnerships with skilled lens designers and toolmakers. This enables us to deliver an end-to-end service to our customers - including specialist tool specification and advanced lens design. Whether volumes are high or small, we know that accuracy is paramount; and our hugely experienced in-house technical department will ensure design efficiency and production quality to the standards demanded by the optical industry. Page 4 Tel: +44 (0)1420 470400 Email: plasticmoulding@fernhoward.com Visit: www.fernhoward.com/plastic-moulding
Plastic Moulding We allow lighting manufacturers to reach the high standards of quality and optical precision their industry demands - manufacturing more than one million parts every year. Custom lenses and diffusers for the lighting and diagnostics industries Established relationships with specialist toolmakers and optical design consultants State-of-the-art LED applications for commercial and highway sectors From a few grams to ½ meter width Tel: +44 (0)1420 470400 Email: plasticmoulding@fernhoward.com Visit: www.fernhoward.com/plastic-moulding Page 5
Lens Design Drawing on our own experience, hard-won through the development of our own lighting ranges, we can manage lens design from start to finish. From concept to production: from design and tooling to final manufacture. We work with, and know the value of, specialist optical design consultants, and can select from a range of carefully chosen tooling partners, each one expert in their own field. In this way we achieve high optical and lighting efficiencies, and help our customer s products out-perform their rivals. CAD DESIGN Cost effective solutions for our customers High efficiency for their products Flexible sourcing A stable, UK manufacturing base TOOLING MANUFACTURING TESTING Page 6 Tel: +44 (0)1420 470400 Email: plasticmoulding@fernhoward.com Visit: www.fernhoward.com/plastic-moulding
Plastic Moulding From concept to production Tel: +44 (0)1420 470400 Email: plasticmoulding@fernhoward.com Visit: www.fernhoward.com/plastic-moulding Page 7
Technical Moulding Our technical moulding portfolio is diverse, from low volume components for analytical instruments and small batch, fast response, custom printed USB components to high volume, flame retardant, enclosures for the electronics industry and health-critical parts made from anti-microbial materials for healthcare. Our extensive technical expertise combined with our modern facilities mean we can provide the highest level of service Physically large parts, machine capacity up to 1,000 tonnes Small volumes Short lead times and customisable supply Full portfolio of supporting operations For over twenty years we have produced technical mouldings for industries that include Electronics & Computer Niche Hi-Fi Systems Pest Control Medical Page 8 Tel: +44 (0)1420 470400 Email: plasticmoulding@fernhoward.com Visit: www.fernhoward.com/plastic-moulding
Plastic Moulding Our supporting operations include Ultrasonic Welding Manual Assembly Formed-in-place Gasketing Laser de-gating Printing Tel: +44 (0)1420 470400 Email: plasticmoulding@fernhoward.com Visit: www.fernhoward.com/plastic-moulding Page 9
Formed-in-place Gasketing represented in the UK by Plastic Moulding As the official UK agents of Sonderhoff materials and equipment we have unrivalled expertise of formed-in-place gaskets. Formed-in-place Foam Gaskets Two chemically safe components which, when combined, expand to form a poured two-part gasket. This gasket has no joints and will blend with, and fill, uneven surfaces. It requires no additional fixing and needs no secondary sponge material in order to form a perfect seal. No dedicated tooling is necessary, making this a highly cost-effective solution for customers. The chemistry used is dependent on application, each formulation being tailored to a specific end use these include: Food packaging Automotive and Transport Air conditioning Electronics industry and electronics enclosures Lighting Page 10 Tel: +44 (0)1420 470400 Email: plasticmoulding@fernhoward.com Visit: www.fernhoward.com/plastic-moulding
Plastic Moulding Gaskets for Environmental Protection Seals against Dust and Water A robotised process that is both cost-effective and simple to set up, we offer two variations: Seal integrated with mouldings produced at Fern-Howard OEM gaskets for customers with fabricated sheet or cast metal components Both are cost-effective and flexible. Why use Formed-in-place Gaskets? Unlike other methods such as die-cut gaskets or jointed neoprene cord, Formed-inplace gaskets provide: High performance A perfect fit to any shape - flat, grooved or complex three-dimensional Ease of assembly (the gasket adheres to the product, cannot fall out, and so makes assembly easy) Cost savings due to reduced material Cost savings on tooling (die-cut gaskets require a new tool for each gasket size, formed-in-place can produce gaskets on demand, from the same tool.) Reduced stockholding and inventory Faster production mouldings delivered with gaskets already in place Tel: +44 (0)1420 470400 Email: plasticmoulding@fernhoward.com Visit: www.fernhoward.com/plastic-moulding Page 11
Turnkey Operations Taking products from initial design through prototyping and toolmaking to production Working as your manufacturing partner we can take products from the most preliminary of design sketches through to validated production mouldings. We have experienced in-house project management and technical support teams, advanced CAD and prototyping facilities. Our established network of tooling partners and our own tool room means we can manufacture, maintain and modify your tools, whilst our thermoplastic expertise means we can source, develop and test the plastic compound best suited to your job. We simplify and streamline the entire injection moulding process. Page 12 Tel: +44 (0)1420 470400 Email: plasticmoulding@fernhoward.com Visit: www.fernhoward.com/plastic-moulding
Plastic Moulding Our Plant Machine Type Quantity Tonnage Max Shot Weight (PS in g) Tie bar distance (mm) Max/Min mould heights (mm) Negri Bossi 1 1,000 5621 1300 x 1100 1200/500 Negri Bossi 1 750 3570 900 x 1000 1000/400 Negri Bossi 2 440 1645 760 x 680 800/250 Negri Bossi 1 330 849 660 x 600 730/220 Negri Bossi 2 270 760 630 x 570 700/280 Negri Bossi 4 210 435 570 x 510 630/200 Negri Bossi 4 160 380 450 x 510 550/170 Negri Bossi 1 85 155 400 X 360 450/150 Arburg 1 70 121 320 x 320 400/200 Arburg 2 50 89 320 x 320 550/200 Arburg 1 35 41 221 (2 tie bar) 300/150 Finishing Capabilities Hand finishing Ultrasonic welding Laser de-gating Formed-in-place Gaskets Printing Insertion and assembly Tel: +44 (0)1420 470400 Email: plasticmoulding@fernhoward.com Visit: www.fernhoward.com/plastic-moulding Page 13
Fern-Howard is a long-established injection moulding company with extensive experience in the lighting and general moulding industries. Manufacturers of our own, highly successful commercial lighting ranges, we are commercially stable and UK based with a skilled and experienced workforce. Able to undertake most injection moulding commissions up to 3.5kg shot weight both long-run and short-run, we have full finishing and toolmaking facilities on site. Quality assured to BS EN ISO 9001: 2008 Our continuous improvement programs ensure that we deliver the best possible service to both internal and external customers. All products are Designed & Manufactured in the UK represented in the UK by Plastic Moulding COMPLETLEY CONFIDENTIAL You can trust us with your design To find out more about our capabilities, for a quotation or simply for more information: Fern-Howard, 2 Newman Lane, Alton, Hampshire, GU34 2QR, United Kingdom. Tel: +44 (0)1420 470400 Email: plasticmoulding@fernhoward.com www.fernhoward.com/plastic-moulding FHL15001 Issue 1 May2016 Registered in England Reg. No. 3202749 We reserve the right to alter specifications without notice in accordance with our policy of continuous product improvement. Design and copyright rights reserved and our standard Terms & Conditions apply.