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Chris Passanante, GMN
By Chris Passanante | Jan 8, 2019
Elite Plastics rebranded as GMN Plastics

GMN is welcoming the new year with exciting changes! Effective today, we are rebranding Elite Plastics to GMN Plastics. In addition to unifying the company’s different brands (GMN Aerospace and GMN Automotive), the new name and logo will continue to put the focus on our plastic services, while also reflecting the full extent of the vertically-integrated capabilities and solutions that GMN can provide.

This rebranding initiative has allowed us to reflect on all the successes we have celebrated as “Elite Plastics”, and everything we aspire to achieve as “GMN Plastics”. We hope to embark upon a new journey in the growth of our plastics capabilities and services under the new brand name, GMN Plastics.

To learn more about the rebranding, read our press release here.

By Neha Toshniwal | Sep 18, 2018
GMN to exhibit at NEDME 2018 in Beaverton

GM Nameplate (GMN), along with its plastics division - GMN Plastics, will be exhibiting at the NW Electronics Design & Manufacturing Expo (NEDME) in booth #M103. The event will take place at Tektronix in Beaverton, Oregon on October 3rd, 2018.

GMN will be showcasing a wide array of our capabilities ranging from injection molding to front panel integration, and plastic decoration to capacitive touch. Our onsite technical experts will also be sharing the latest technological developments at GMN. One of our core strengths lies in translating concepts into concrete creations. From development and production of individual components to complete value-added assembly, GMN provides a holistic approach by delivering a plug-&-play user interface.

We are happy to set up one-to-one meetings to discuss how GMN can support your varied manufacturing needs. To schedule a meeting with a technical expert, please reach out to us directly at info@gmnameplate.com.

By Kenny Pravitz | May 3, 2018
Value-added assembly is a process where the value of an article is increased at each stage of manufacturing.

There are typically a variety of pieces and processes involved in making a complete part. As a result, customers sometimes require several different suppliers to make each specific component of the assembly. Even smaller products can have a long list of components and suppliers. During the manufacturing process, costs can vary greatly and the time it takes for products to be completed depends on a range of factors, one of them being how long the supply chain is. In general, a shorter supply channel means your products will get to market quicker, with fewer costs. A great way to shorten your supply chain can be to partner with suppliers that offer value-added processes, or can provide multiple different services or aspects of production.

Value-add can be defined as a process where the value of an article is increased at each stage of its manufacturing, bringing an enhanced benefit and cost savings to the customer.

As a value-added supplier, GM Nameplate’s (GMN) plastics division in Beaverton, OR created a video that demonstrates the value-added assembly process of a medical part. In this video, you can see the stages that these molded parts go through to reach the completed subassembly. Similar to most projects at GMN’s plastics division, the process begins with injection molding. Once that part is molded, it can be decorated, depending on what the customer wants. Offering different decorating options, such as screen printing or hot stamping, after a part is formed is an example of a value-added benefit.

In the video, an operator can be seen placing 17 brass inserts in different bosses of the molded part. To make sure the inserts are properly installed every time, the operator places the molded part in a poka-yoke (Japanese term for “mistake-proofing”) fixture. The molded part will only fit in the fixture one way, so the operator installs the inserts into the correct bosses. These inserts are then heat staked, where a heating element makes contact with each brass insert. The insert then transfers heat to the boss, melting the plastic around the screw. This enables the screw to be removed without stripping the plastic.

Next, the video shows the part being placed in another fixture where a three-camera vision system verifies all the inserts were properly installed. This vision system also has a poka-yoke fixture to ensure consistent verification. Once the vision system notifies the operator that all inserts were properly installed, the part moves to the next value-add station. We see the molded part moved to an assembly fixture where a blue latch-spring component (which is also injection molded by GMN) is assembled to the main plastic enclosure. After this, an operator installs gasketing to the perimeter of the part. Finally, the part is inspected and then packaged for shipment.

From beginning to end, multiple different components and processes were used to make this part, all under one roof. This added value allows customers a cost savings as well as a streamlined supply chain, as several components were completed by one manufacturer, instead of multiple vendors for each individual operation. GMN takes a holistic approach to building your device, and the breadth and depth of our internal capabilities bring increased control, predictability, and reduced costs to your supply chain.

To watch this process in action, click play on the video below. 

By Kenny Pravitz | Mar 27, 2018
A softer plastic resin can be over-molded to a rigid plastic all within the same process with two-shot molding.

When you look at or feel a plastic component, you would usually assume that it’s made of one type of plastic. However, some plastic products are actually made using two different types of resin, sometimes more. You are probably familiar with this application which can be seen in plastic toothbrushes that have a rubberized grip. The main body of the toothbrush is made of a rigid plastic, while the grip is made of a rubberized plastic. Even though there are two different types of plastic present, both were formed at the same time using two-shot molding.

GM Nameplate’s (GMN) plastics division in Beaverton, OR recently created a video that demonstrates this two-shot molding process. The process is called two-shot molding because there are two different resins being injected by two separate barrels. There is a primary barrel, which injects the first resin, forming a rigid substrate in most cases. The secondary barrel then injects a different resin on top of or surrounding the region of the first substrate.

Depending on the size and intricacy of the part, you can design the tool to make several parts in each cycle. In the video, we see that two parts are completed during each cycle. On the left side, the rigid substrate is injected by the primary barrel and forms the backbone of the two components. The tool then rotates 180 degrees, and the rubberized plastic is injected onto those two pieces by the secondary barrel. While this is being done, two more rigid substrates are made at the same time again by the primary barrel on the left side. After the pieces are injected by the secondary barrel, an end-of-arm tool picks up the completed parts, and then the tool rotates 180 degrees once more, ready to start a new cycle.

Two-shot molding is ideal for higher volume projects, as more engineering is used in designing the two-shot molding tool. The tooling used for two-shot molding is intricate because it must inject two different plastic resins simultaneously, but only in certain features of the part. Two-shot molding is a much more efficient process for high-volume projects compared to conventional over-molding, where you use two separate tools to manufacture parts with different resins. Due to this efficient output, two-shot molding is frequently used in the automotive and medical industries.

Click on the video below to see the two-shot molding process for yourself!

By Kenny Pravitz | Jan 30, 2018
IMD allows different graphic overlays to be used in the same molded shape, giving  you customization.

Many industries require the decorative elements of plastic to be highly durable. For example, the aerospace, automotive, and medical industries have many high-wear applications that require strong, durable parts where printed icons won’t scratch off or fade away. Products that are decorated using first-surface decorating processes, where graphics are placed on the outermost layer (such as pad printing, screen printing, or hot stamping), wear out over time and aren’t suitable for these industries. Depending on the materials and processes used, the inks on plastic pieces can fade out over time, making it difficult or impossible to read indicators on those pieces.

In-mold decorating (IMD) is a plastic decorating method that ensures the durability of the graphic overlays and allows for multiple design options for the overlays. In brief, IMD is a process where a graphic overlay is physically fused to injection molded plastic to form one piece. Molten resin is injected either in front or behind the graphic overlay to form a bond between the two. Unlike pad printing, screen printing, or hot stamping – where inks and overlays are exposed to the user that can deteriorate over time – IMD parts have a layer of plastic that encapsulates the ink, protecting it from users and the outside environment.

GMN Plastics, GM Nameplate’s (GMN) plastics division in Beaverton, OR, recently created a video that demonstrates the IMD process. In the video, we see an end-of-arm tool pick up a graphic overlay and place it in the injection mold using a vacuum system, while simultaneously removing a part that was just molded. Both of these functions are completed in one cycle, allowing for faster and more efficient production. Locating pins in both the end-of-arm tool and injection mold itself allow for consistent placement of the overlay in the tool, which is critical for functional parts in regulated industries. If the overlays are not correctly and consistently placed in the mold, some portions of the overlay may not be fully encapsulated by plastic during the molding process.

IMD is ideal for higher volume projects that have stringent durability requirements, as there is more design engineering required up front than with a standard injection molded part. However, one advantage is that once the graphic overlay and molded part is designed, printed graphics on the overlay can be changed at any time to allow for customization and unlimited design options.

To learn more about what the IMD process is, read this blog.

To watch the IMD process, click play on the video below. 

Chris Passanante, GMN
By Chris Passanante | Jun 23, 2017
ISO 13485

Due to our ongoing commitment to the medical device industry and growing demand, GM Nameplate’s (GMN) Beaverton, OR Division attained ISO 13485:2003 certification. The Beaverton, OR Division, GMN’s dedicated plastics facility, received this certification after auditing and approval by the Orion Registrar on May 9, 2017. This ISO standard is in regard to the quality management system requirements specific to medical device manufacturers. GMN’s Beaverton, OR Division is the third GMN division to obtain this quality certification.

What does this standard mean for GMN customers?

Meeting the strict standards of ISO 13485 assures that GMN can continue to support existing and future customers in the medical industry. ISO 13485 demonstrates that GMN meets regulatory standards and legal requirements to operate in the medical device industry, reduces risk effectively, and has systems in place to consistently yield safe and effective medical device components.

With little room for error in the medical industry, GMN has continually worked to uphold a quality system that meets the highest quality standards in order to produce best-in-class solutions. This certification validates the strength and sustainability of our processes which differentiates us from competitors.

Dedication to quality

For decades, GMN has shown commitment to the medical device industry and a dedication to creating quality products. Compliance with ISO 13485 ensures that the medical device components and sub-assemblies produced by GMN will meet or exceed thoroughly planned specifications every time, without exception.

As a company that supports multiple regulated industries, such as medical, we are committed to ensuring that our Quality Management System is robust and flexible enough to meet the variety of challenges presented by our wide range of customers and industries. With this new recognition, GMN’s Beaverton, OR Division shows its ability to handle increasingly stringent and diverse customer requirements. In addition, the ISO 13485 compliments ISO 9001, another quality standard that GMN has long been in compliance with, which reflects our continual efforts to broaden our quality system to better align with the current Good Manufacturing Practices.

GMN employee Dave Hauskins
By David Hauskins | Sep 8, 2016
Custom molding process for battery packs

GMN Plastics has been involved in a program for one-time battery packs used in downhole oil and gas drilling test equipment. These battery packs are exposed to extremely high levels of heat and pressure, so their casing is made out of a high glass fiber content and high temperature resistant material. This combination allows the part to withstand its intense environmental conditions.

A single part is molded and then CNC (Computer Numerical Control) machined to create the top and bottom housing for the pack. After the machining process, the part is pad printed with high temperature resistant ink.

However, the part’s high glass content causes complications during the molding process, such as non-linear warping, which can make it difficult to ensure that the surfaces of the part come out flat and smooth. The customer has strict requirements regarding flatness, so the team at GMN Plastics had to modify its manufacturing process in order to align with their expectations. Through various tool and process adjustments, the team successfully created a process to manufacture and assemble the battery packs with smooth surfaces that met the customer’s requirements. 

Bruce Wold, GMN
By Bruce Wold | Aug 4, 2016
Designing for manufacturability

A very important aspect of project planning is assessing the design and providing design considerations for part manufacturability. During this phase, GMN Plastics program managers and engineers are looking for anything that might cause problems in the molding process including both cosmetic and dimensional issues. Typical issues include wall thickness, wall to rib ratio, draft angles, boss diameters, undercuts, weld line locations, and texture choices. GMN Plastics solves this problem with years of experience and state-of-the-art software simulators that allow engineers to get a closer look at the part by dissecting it into smaller pieces. These tools can help identify these issues so that they can be solved prior to production.

One of the main issues faced during project development is wall thickness. The wall thickness depends on many factors and there is no density that works universally for all projects, so it must be customized per part. Wall thickness is important because it affects processing of the part and depending on how far the material needs to flow, this can affect both cosmetics and dimensions. If the walls are too thin than the melted plastic moves slowly through the tool, which makes it difficult to fill. On the other hand, if the walls are too thick than it takes longer for the plastic to cool, which can cause part shrinkage. This happens because the areas of plastic on the outside cool more quickly than the inside, which can cave in. Where possible, there needs to be even wall thickness and smooth transitions for the material to flow through correctly.

Wall to rib ratios are another important consideration during part design.  Ribs are commonly used in plastics manufacturing as a way to increase the strength of the part structurally. It’s important to note that rib thickness must be 60% or less than the wall thickness of the part or the ribs will sink and be seen through the other side of the part. 

One of the main considerations during injection molding manufacturing is the part draft angles. This is because the part needs to be able to get out of the tool and to do this there cannot be a 0 degree, or exactly perpendicular, draft. A 0 degree draft angle would cause the part to get stuck inside the tool. A part with heavy texture will need to increase the draft angles even more because the plastic is more likely to stick to the tool. The key takeaway here is that correct draft angles will make the part look good without getting stuck.

Boss diameters, the holes where screws are inserted, are important to consider too. The boss diameter needs to be the right size because it typically holds a metal insert which needs to fit in correctly. If the boss wall is too thick, there will be sinking on the other side of the part. If the diameter is too small, the insert will not fit in the hole. There are industry specific standards based on each manufacturer.

An undercut can be defined as a recessed area of the part, and in terms of molding this means that the undercut area makes the part unable to release out of the tool. The plastic is injected around the undercut feature and the part cannot be ejected because the shape curves inward. The part is stuck because the plastic has formed around the tool which causes problems during production.

Weld lines are a cosmetic issue for consideration. A weld line occurs when the material wraps around a feature and comes back together around an obstruction while filling the tool. When this happens, a small line is formed called a weld, or knit, line. This needs to be considered during part design because the weld line is tricky to hide. When determining the location of a weld line it is important to look at the plastic temperature, gate location, speed of flowing plastic, gate thickness, gate location, and gate height.

Texture can be used to hide molding flaws. For example, when the part design will give you sink a heavier texture can help to hide this. Using texture like this has a lot of tradeoffs in design and many customer negotiations occur.

During the stage of project planning when part design occurs, all of these factors are critical to build a successful part that meets customer specifications. The main issues to consider in regards to part design include wall thickness, wall to rib ratio, draft angles, boss diameters, undercuts, weld lines, and texture. 

Denys Sanftleben, GMN
By Denys Sanftleben | Jun 29, 2016
Pad printing at Elite Plastics

At GMN Plastics, we go beyond the standard injection and compression molding processes to offer full solutions to our customers through secondary processes. Within these secondary processes, we offer a range of plastic decorating capabilities in-house in our Beaverton, Oregon facility. These decorative technologies include pad printing, screen printing, hot stamping, vacuum metallization, painting and laser etching, and insert mold decorating.

One of the standard decorative technologies at GMN Plastics is pad printing. Through this printing process, ink is transferred from the cliché and is applied to the part via the pad. To do this, the artwork is etched onto the cliché, a flat plate, and ink is deposited into the grooves of the image. From there, the pad comes down on the cliché and picks up the image before transferring it to the part. At GMN Plastics, there are two types of pad printing machines including a programmable micro printer and standard pad printers. The difference between the two types is that the standard machine is equipped with stationary fixtures while the programmable printer is able to move the fixture so that the part can be printed on at multiple angles. Another major strength of pad printing compared to other decorative processes is the ability to print multiple colors during one set-up rather than through individual set-ups per color. This saves crucial time and money for the program. Pad printing is able to achieve fine print graphics as well.

Considerations when evaluating pad printing as a decorative option include the type of plastic material and the size of the artwork. If the plastic material being printed on has a heavy textured finish, the ink may not print as crisply or thoroughly as it would on a smooth material. Some plastic materials aren’t cohesive with inks and require a pre-treatment to ensure good adhesion. After production, a post-treatment is done to ensure that the ink is cured quickly. Despite these considerations, pad printing technology is highly recommended for its ability to achieve multiple colors and angles in one run.

In our next article we will discuss screen printing technology and its application for plastic parts. 

 

Edward Laffert, GMN
By Edward Lafferty | Jun 10, 2016
Plastic molding machine for the annealing process

In simple terms, annealing is a manufacturing process of heating a material up for a period of time before allowing it to cool down. This capability can be applied to all three types of basic materials, ceramic, metal, and polymer, but we focus on plastic material here at GMN Plastics. In the plastics industry specifically, annealing is the process of heating a plastic part up to half of the melt temperature for a moderate period of time before letting the plastic cool back down. When the part is reheated like this, the material relaxes and the molded stress is reduced. Annealing is a secondary operation, specifically a heat treatment, and isn’t typically done for all plastics parts or even in most plastic industries, but it is an important technology here at GMN Plastics.

This is an important step of the molding process because most plastic materials are poor conductors of heat which can lead to part damage. Because the plastic parts are heated up to high temperatures through annealing, the material is able to relax so that it does not react to stress caused by molding when it is in its final application or shape.  These stresses typically include tension or compression (built-in stress or molded stress).

The purpose of annealing can vary for different plastic materials, but GMN Plastics uses it to ensure part stability over time. This is important for two main reasons. First, by reducing the stress, the plastic part will have better mechanical and thermal properties because there are fewer sites in the polymer that could propagate a crack or expand the part. Secondly, because most of the plastic parts that GMN Plastics produces are painted, a crack would be very visible against the paint. This is because the part material will contract and expand over time and if it has not already experienced this fluctuation at a more extreme condition through annealing, it will noticeably crack.

 While the annealing process is not used in every plastic industry, GMN Plastics is committed to utilizing the technology to ensure plastic part quality over time. 

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