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FACILITIES
Design and Engineering
Office
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Design and Engineering
Office: Extreme Tool and Engineering's,
Engineering Department is the Foundation of its operation.
(6) Seats of Pro Engineer Software are employed, for all aspects
of the manufacturing process. Pro E is used for Product Design,
Mold Design, Electrode Design, CNC Programming, CMM Programming,
and Mold Flow Simulation/Analysis. Management is committed
to training employees as req'd to allow them to use these
tools to the fullest. Progress is being made on development
of a qualified and committed 2nd shift engineering staff using
these same tools, allowing design and programming activities
20 hour's + per day, allowing additional opportunities for
delivery improvement. Staff is highly skilled and versatile
with individuals present with strong moldmaking background
and others possessing engineering degrees and more formal
education. A total team effort by customer driven/responsive
individuals guarantees your project the best possible opportunity
for success!!!
Milling/Roughing
Department
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Milling/Roughing Department:
A complete compliment of modern, well maintained manual toolroom
equipment is present in our roughing department, including
Bridgeport Mills and Radial Arm Drill Press. Most heat treating
is completed in house using programmable heat treat furnace
on site allowing fastest possible component manufacture. Every
Steel component heat treated is tested for Rockwell Hardness
at completion and results are documented. In house TIG welding
capability as well for engineering changes and repairs as
req'd.
CNC Machining
Department
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CNC Machining Department:
Extreme Tool's CNC Dept. is a modern/progressive component
in the Extreme Tool Mold Manufacturing System. The Hub of
this department is our Roders 600 High Speed Graphite and
Hard Steel Mill. This machine offers high speed spindle/heat
shrink balanced toolholding (42,000 RPM) as well as high speed
feed rates (1,200 IPM) and super accuracy. Machine used to
manufacture all electrodes req'd as well as Hard Steel Milling
with efficient transition between these manufacturing requirements
accomplished via. 3R Pallet System. (2) Haas VF1 CNC Machines
used for conventional steel machining have proven to be robust/reliable
work horse machines. CNC programming office recently completed
directly adjacent to machining operations allows efficient
access/communication between CNC Programmers and Operators.
Most recently a Makino V55 High Speed Mill has been added
to provide additional Accurate, High Speed, Hard Steel Milling
capability.
Mold Finishing/Assembly
Area
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Mold Finishing/Assembly Area:
All final fit, assembly, and grinding occurs in this area.
Layout of this department allows assembly, final fit, and
component grinding of multiple molds simultaneously. Equipment
present includes the best available including grinders by
Mitsui and Okamato.
EDM Department,
Sinker and Wire
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EDM Department, Sinker and Wire: State
of the art, fully automated CNC Machines present. Mitsubishi
EX22 Sinker EDM's present have 32 position tool changers with
3R Combi Chuck and dual magnets allow multiple work piece
machining 24 hours a day, 7 days a week. (2) Fanuc 1iB CNC
Wire EDM's offer large work area/table travels and ultra reliable
auto threading allowing efficient, unattended 24/7 machining
capability. Small hold drilling/hole popper present allows
starter drills in most difficult applications.
Molding Area: All molds produced have
tryout/debug completed before they ship, and low volume production
can be completed when desired. 150 ton TMC Molding machine
available with servo robot as well as 28 and 80 ton presses
in class 100,000 cleanroom environment. Full material handling
and drying capability present as well as thermolator's and
Hot Oil controllers for high temp applications. Sonic Welding
Capability and Assembly Operations present in class 10,000
clean room environment for medical and electronics applications.
Services offered in the department include mold trials, capability
studies, process development/DOE, Horn and Fixture Development
(sonic welding), EOA Tooling design, manufacture, and development.
Since we are not a production molder, these capabilities are
most often available at very short notice, allowing us to
provide very agile response to customer requirements at project
completion time. Many of our customers find it easier to complete
these tasks here rather than at their own facilities, and
we continue to add services to meet their needs. In house
startup at their facilities is easier due to these items being
completed before mold ships.
Quality Area: A fully
equipped quality lab is present with full time ASQC Certified
quality technician on staff. Modern/State of the Art Inspection
Equipment present including Brown and Sharp Fully Automated
CMM, OGP Smart scope (automated vision system), Nikon Toolmakers
MicroScope, and full compliment of calibrated, conventional
gauging. Quality Services offered are customer specific solutions
and include First Article Inspection, Capability Studies,
SPC, full PPAP including all req'd flow charts/FMEA's, etc.,
Steel Certifications, etc. Our goal is to provide an agile,
accurate, timely solution. All molds are shipped with an organized
packet of information that includes all program related documentation
developed for the tool being shipped.
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Conference Room: Conference
Room present is where all project and program meetings take
place and is often the epicenter of customer visit's, samplings,
etc. Examples of successfully completed programs surround
the room and often provide good visual aids during brain storming
sessions. Permanently Mounted projector and conference calling
capability add functionality here, and access to internet
available to all via. high speed T1 dataline.
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