|
COMPETITIVE
MANUFACTURING PROCESSES:
All these processes have the
ability to create hollow enclosures of various shapes (box, pyramid,
sphere, etc.). But not ALL shapes, like US Enclosure
equipment produces.
1. Resin Transfer
Molding( RTM) and Vacuum
bagging (SCRIMP,
RIFT, VARTM, etc). These processes have low tooling cost and
are relatively easy to set up. However, these processes do not
produce a Class A
finish. The use of injection ports in the case of RTM
and a wrinkly bag in the case of vacuum bagging guarantees either/or
several out-of-mold scars / class D quality finish. Equipment
costs also are high.
2. Filament
winding. This is a horribly expensive and complex process,
topped off with a bad exterior finish. The only current applications are
for extremely high pressure
tanks such as SCUBA gear and other similar applications.
Extremely Costly.
3. Injection
molding. Legendary tooling costs, as in, don't bother
with this process unless you want to do at least 100,000 quantity
and have
equally incremental dollar amounts to spend. Enclosure sound
quality is abominable . Complete enclosures
are problematic, typically injection-molded enclosures are molded as
several pieces which then have to be assembled by hand or machine at additional
cost. And for all this, one still has problems with fibrous
or granular additions, extremely high energy consumption, shape and size
limitations. Class A finishes can be difficult or impossible to
achieve. Very Costly. Cabinets are low density.
4. Compression
molding. Large, bulky, heavy equipment approach, similar to
injection molding but not as limited in size. Typically used for
fenders, body panels; automotive-size pieces. Most parts still
need to be painted. No Class-A finish out-of-mold. Very Costly.
5. Blow molding.
Typically used for bottles. Fibrous materials can be added, prepreg
molding is a variation on the theme. Tooling is expensive but
finishes can be good. However energy consumption is high.
Equipment cost high.
6. Solid
printing or stereo lithography is an interesting but expensive and
time-consuming process with additional finishing requirements.
7. Rotomolding
is an expensive process to set up with some of the highest energy
consumption levels of any of these processes. High quality
finishes are difficult to achieve. The process can be very
sensitive to ambient conditions such as humidity. Run quantities required are moderate to high.
|