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.