Cost-effective low-pressure moulding using Macromelt

Mobilarm, a global manufacturer of man overboard rescue systems for the marine industry, is now using low-pressure moulding with Macromelt to replace a previously subcontracted service. The project to bring Macromelt moulding in-house has not only saved on subcontract costs, it has reduced scrap rates and introduced new-found levels of flexibility into the company's manufacturing and prototyping processes.

Although headquartered in Perth, Australia, Mobilarm's European operation is located in Beverley, UK, where the main focus of manufacturing is the company's Sea Marshall range of man overboard systems, or to give them their industry name: Maritime Survivor Locating Devices (MSLD). These innovative units transmit a continuous homing signal on a frequency of 121.5MHz, which is detected and tracked on a Mobilarm base unit aboard the parent vessel. The signal can also be tracked by international search and rescue operations. First launched in 1979, Sea Marshall is now the leading MSLD system in the North Sea, where over 5000 units are in daily use.

Until recently the company was subcontracting its requirement to encapsulate part of the aerial unit on the Sea Marshall system. Here, a small cable connects to a PCB that features side-firing LEDs. Part of the configuration is a delicate antenna spring that requires encapsulation.

Ian Pinder, Production Manager at Mobilarm Europe, explains: "When we first started product encapsulation, our supplier was producing overmoulds using conventional injection moulding techniques. However, there was insufficient grip at the cable end so we extended downwards, effectively doubling the size of the overmould. This solved the gripping problem, but because the larger overmould required greater pressure and temperature to achieve the required flow, components were literally being blown off the PCB. We were getting 40 per cent fall-out rates, which was completely unacceptable."

In the hunt for an alternative process, a series of web searches and telephone calls led to the door of Engineering Solution, which through its partnership with Henkel, provides manufacturers across a host of industry sectors with a low-pressure moulding service complete with machine, aluminium mould tools and Henkel's Macromelt. Macromelt moulding is in a category between casting and injection moulding. It is non-aggressive, highly cost effective and fast. Because low pressures are involved, typically 2-20bar, lower cost mould tools can be employed. And of course the technology is suitable for encapsulating and enclosing delicate components and assemblies, providing protection from vibration fatigue and atmosphere/liquids that could promote corrosion or conductive paths.

Greatly reduced failure rate

Installed 18 months ago at Mobilarm's Beverley facility, the system is delivering a host of benefits, as Mr Pinder confirms: "Our failure rate has dropped to 1 per cent," he says, "and to be honest, this typically results from a PCB failure or bad joint in manufacturing - we can safely say that Macromelt is 100 per cent successful."

Approximately 10g of Macromelt is used for each Mobilarm overmould, which encapsulates the electroplated steel antenna spring and PVC cable. The overmoulds, which are produced using an HB-500 ESL hand-held machine and single-stage aluminium mould set, measure around 50mm in length and 20mm in diameter. The operating pressure is 5bar, while temperature is 220-230degC. The cycle time is around 30s in jet with a further 30s required for cooling - vastly superior to traditional potting methods. The Beverley site currently produces around 1000 overmoulds every month.

Mr Pinder states: "The system has more than paid for itself already. Not only have we saved the cost of subcontracting, but the 40 per cent fall-out rate has been eliminated. Furthermore, while we could recycle the cable and antenna spring from rejected systems, we had to write-off the cost of the PCB and the overmould."

Looking forward, Mobilarm is currently developing a new beacon variant that features a modification to the antenna - there is now a GPS module on the side. Engineering Solution has provided an aluminium mould set and prototype units are already being produced.

Mr Pinder says: "The Macromelt system is so quick and cost effective that it not only aids a far easier prototype phase - project costs are reduced dramatically - it also supports tremendous flexibility in manufacture. We no longer require a batch of 500 to justify the cost of injection moulding. If we only need 10, for example, we can make them quickly and inexpensively."

To find out more about low-pressure moulding with Macromelt, go to www.henkel.co.uk.

Henkel Ltd

Wood Lane End
Hemel Hempstead
HP2 4RQ
UNITED KINGDOM

+44 (0)1442 278000

technicalservice.loctite@uk.henkel.com

www.henkel.com

More from Henkel Ltd

Henkel’s Technomelt in a mould of its own

Posted 2 weeks ago

Fast and durable plastics bonding

Posted 1 month ago

Five day machine repair reduced to 8 hours

Posted 2 months ago

Threadlocker makes light work of solar panels

Posted 4 months ago

New repeatable threadlocking dispenser

Posted 4 months ago

Henkel Loctite highlights advantages of threadlocker

Posted 5 months ago

Dangers of vibrational fastener loosening

Posted 6 months ago

Beware of the gap when locking threaded fasteners

Posted 7 months ago

Loctite threadlocking webinar: 1100 GMT Tues 22nd September 2020

Posted 9 months ago

Quarry managers develop crush on LOCTITE

Posted 1 year ago

LOCTITE introduces larger adhesive pack size

Posted 1 year ago

Online support and CPD for users of threadlocking adhesives

Posted 1 year ago

Repair rubber components quickly and reliably

Posted 1 year ago

New packaging combats threat from counterfeiters

Posted 1 year ago

See Henkel's latest developments at Southern Manufacturing 2020

Posted 1 year ago

Pipe sealing products set to prove popular among plant engineers

Posted 1 year ago

See Henkel's latest developments at Southern Manufacturing

Posted 1 year ago

Epoxy coating suits abrasive and hot applications

Posted 1 year ago

Henkel offers free guide to leakage prevention

Posted 1 year ago

How to increase plant reliability and reduce operational costs

Posted 1 year ago

Henkel eShop is added-value resource for adhesives and sealants

Posted 2 years ago

Henkel opens European hub for 3D Printing technology

Posted 2 years ago

Henkel's Loctite 3D printing materials at Southern Manufacturing

Posted 2 years ago

Construction starts on Henkel's new Global Innovation Centre

Posted 2 years ago

Gasket sealant now available as a roller pen

Posted 2 years ago

Conveyor belts repaired in less than two hours

Posted 2 years ago

Cost-effective anti-spatter from Henkel

Posted 3 years ago

Henkel unveils Bonderite functional coatings website

Posted 3 years ago

Henkel to be global reseller of HP Multi Jet Fusion 3D printers

Posted 3 years ago

New hybrid, emergency repair adhesive for highly durable bonds

Posted 3 years ago

See Henkel LOCTITE at Southern Manufacturing 2018

Posted 3 years ago

Efficient sealing systems in fluid power applications

Posted 3 years ago

How to prove structural bonder's speed, strength and durability

Posted 3 years ago

Anaerobic sealants introduce new performance benefits

Posted 3 years ago

Hybrid structural bonder copes with heat and vibration

Posted 3 years ago

Loctite retaining compounds benefit from improved formulation

Posted 3 years ago

New hybrid adhesives for exceptional and safe performance

Posted 3 years ago

Remote assistance with internet-connected "˜smart' glasses

Posted 3 years ago

Loctite HY 4070 structural bonder for maintenance and repair

Posted 3 years ago

How to prevent threaded joints from working loose?

Posted 4 years ago

How can 3 grams of structural adhesive pull a 208 ton train?

Posted 4 years ago

New Universal Structural Bonders for dissimilar substrates

Posted 4 years ago

Featured application

Posted 4 years ago

Bonding systems: A track record of safety and success

Posted 4 years ago

Henkel innovations underpin automotive lightweighting

Posted 4 years ago

LOCTITE threadlocking adhesives better than ever

Posted 4 years ago

Ultra-safe, responsibly formulated hand cleaners

Posted 4 years ago

Lubrication - when is anti-seize the best choice?

Posted 4 years ago

Henkel launches dedicated YouTube channel

Posted 4 years ago

LOCTITE chosen for arduous, sub-zero conditions

Posted 4 years ago

See Henkel LOCTITE at Southern Manufacturing 2017

Posted 4 years ago

Rooflight manufacturer partners with Henkel

Posted 4 years ago

Henkel to present bonding products at K 2016

Posted 4 years ago

LOCTITE Maintenance Expert pocket guide is updated

Posted 4 years ago

Henkel equipment - the full works with upgraded website

Posted 4 years ago

Anti-seize in a stick - LOCTITE LB 8065

Posted 4 years ago

Henkel's LIS: fast and reliable fix for the automotive industry

Posted 4 years ago

Wider scope of application for gasketing adhesive

Posted 4 years ago

Henkel opens new composite test centre: The Composite Lab

Posted 4 years ago

Henkel Adhesives at the European Championship in soccer

Posted 5 years ago

Henkel practises what it preaches with pipe repairs

Posted 5 years ago

Henkel announces functional coatings "˜TechDay' in Birmingham

Posted 5 years ago

LOCTITE coating extends lifetime of flue gas duct

Posted 5 years ago

Be among the number: 1000 prizes & Henkel's "˜Grand Prize Draw'

Posted 5 years ago

Improved Loctite thread sealant resists higher temperatures

Posted 5 years ago

Henkel and the NextEV TCR racing team: Formula E hits Europe

Posted 5 years ago

Dual volumetric rotor pump for latest generation adhesives

Posted 5 years ago

Henkel's hotmelt restores the boy king's mask

Posted 5 years ago

Henkel webinar: how to seal your powertrain flanges

Posted 5 years ago

Free webinars: learn what you need to know about adhesives

Posted 5 years ago

Efficient sealing systems in fluid technology

Posted 5 years ago

Popular Loctite webinar series extends into 2016

Posted 5 years ago

Recognition worldwide for Henkel products

Posted 5 years ago

Henkel's adhesives experts help restore Pharaoh's mask

Posted 5 years ago

New Structural Bonding webinar added to Loctite programme

Posted 5 years ago

New Henkel literature and video for LOCTITE 4090

Posted 5 years ago

Adhesives cut costs and turnaround time, and improve aesthetics

Posted 5 years ago

Henkel at Southern Manufacturing 2016

Posted 5 years ago

Adhesives provide reliability despite repeated shock loading

Posted 5 years ago

Loctite adhesives bond 3D printed parts for immediate assessment

Posted 5 years ago

Henkel: recognising outstanding partnership

Posted 5 years ago

Threadlockers ensure reliability for specialist vehicles

Posted 5 years ago

Adhesive helps to improve lean manufacturing of valves

Posted 5 years ago

How to improve machine reliability using threadlocking adhesives

Posted 5 years ago

Explainer: threadlockers, sealants and anti-seize compounds

Posted 5 years ago

LOCTITE products foster success at companies in new campaign

Posted 5 years ago

LOCTITE Health & Safety adhesives continuously developed

Posted 5 years ago

New brochure explains benefits of adhesives for machine building

Posted 5 years ago

Furniture manufacturer exploits the benefits of Bonderite

Posted 5 years ago

Henkel expands expertise in surface treatment

Posted 5 years ago

Improve threaded fastener reliability with anaerobic adhesives

Posted 5 years ago

Instant adhesive is flexible and achieves excellent sealing

Posted 5 years ago

Loctite seminar and webinars in September

Posted 5 years ago

Movie of the month

Posted 5 years ago

Henkel to introduce extended Bonderite range at EMO Milano 2015

Posted 5 years ago

Workshop hand cleaner is now ultra-safe

Posted 5 years ago

Snow video conversion testbed

Posted 5 years ago

What can be achieved with instant adhesives today?

Posted 5 years ago

Henkel at Northern Manufacturing

Posted 5 years ago

Tips for using threadlockers and retaining compounds on machines

Posted 5 years ago

Featured webinars

Posted 6 years ago

Expert advice for students from Henkel

Posted 6 years ago

Adhesive technologies in LED lighting

Posted 6 years ago

New Henkel Loctite Success Secured webinar dates announced

Posted 6 years ago

Henkel unleash full potential of casting value chain expertise

Posted 6 years ago

Step-by-step concrete repair with Loctite Magna-Crete

Posted 6 years ago

Henkel to showcase thermal management expertise

Posted 6 years ago

Henkel adhesives, sealants and coatings for alternative engines

Posted 6 years ago

Henkel honoured with "Excellence Award in Supply"

Posted 6 years ago

Securing fasteners and interference fits on snowmobiles

Posted 6 years ago

Cutting fluids: decreasing process costs, increasing efficiency

Posted 6 years ago

Adhesive dispensing with high repetition accuracy

Posted 6 years ago

Henkel develops first-ever temperature-stable solder paste

Posted 6 years ago

Henkel introduces low-maintenance jet valve adhesive dispensing

Posted 6 years ago

Cost-effective, dependable curing of UV adhesives with LEDs

Posted 6 years ago

Adhesive dispensing with high repetition accuracy

Posted 6 years ago

The product guide with just a little bit more, from Henkel

Posted 6 years ago

Concrete repair that saves labour costs and downtime

Posted 6 years ago

Henkel at Southern Manufacturing 2015, Farnborough

Posted 6 years ago

Loctite - keeping the press rolling

Posted 6 years ago

New mobile maintenance app from Henkel

Posted 6 years ago

Loctite anaerobic adhesive performance further improved

Posted 6 years ago

Henkel announces Supplier Awards for outstanding partners

Posted 6 years ago

Henkel recognises students' adhesive-bonding applications

Posted 6 years ago

Henkel at Northern Manufacturing 2014 with LOCTITE

Posted 6 years ago

Henkel High Tech Adhesives and Coatings Academy

Posted 6 years ago

Henkel increases pipe lifetime by up to 20 years

Posted 6 years ago

New metal-free anti-seize for assembly and maintenance

Posted 6 years ago

Proven hand cleaner conforms to new EU cosmetic regulations

Posted 7 years ago

New generation of Loctite Threadlocker Sticks

Posted 7 years ago

Loctite 5189 sealant used for 1.0L EcoBoost "Engine of the Year"

Posted 7 years ago

Henkel sponsors world-class Formula Student racing team

Posted 7 years ago

Henkel showcases innovative products for industrial customers

Posted 7 years ago

Loctite retaining adhesives 638 and 648 upgraded

Posted 7 years ago

Find new Loctite products at Southern Manufacturing 2014

Posted 7 years ago

Loctite addition repels welding spatter and cuts costs

Posted 7 years ago

Loctite retaining adhesives go from strength to strength

Posted 7 years ago

Henkel claims world's first structural, instant adhesive

Posted 7 years ago

Why use a retaining compound?

Posted 7 years ago

Structural bonding for lighter-weight, energy efficiency robots

Posted 7 years ago

Henkel at Southern Manufacturing 2014

Posted 7 years ago

Crystal clear, high-temperature encapsulating compound

Posted 7 years ago

Adhesive bonding contributes to formula student success

Posted 7 years ago

Maintenance expert in your pocket

Posted 7 years ago

Loctite: the complete range for maintenance, repair and overhaul

Posted 7 years ago

Loctite Live - a nationwide tour

Posted 7 years ago

Loctite 5075 insulating and sealing wrap is multi-purpose

Posted 7 years ago

Ten things machine builders should know about adhesives

Posted 7 years ago

Ten things machine builders should know about adhesives

Posted 7 years ago

New customer web tool, much more than just online ordering

Posted 7 years ago

Health and safety flange sealant silicones

Posted 8 years ago

Perpetuum harvest the benefits of low-pressure moulding

Posted 8 years ago

New elastic adhesive allows instant handling

Posted 8 years ago

Composites help pump repairs to deliver rapid payback

Posted 8 years ago

Adhesives and sealants for equipment repairs

Posted 8 years ago

Henkel and Engineering Solution supply low-pressure mouldings

Posted 8 years ago

Van maker saves 30 per cent on pump energy costs

Posted 8 years ago

New, simpler branding for Henkel industrial adhesives

Posted 8 years ago

New website for surface engineering products

Posted 8 years ago

Loctite instant adhesives at Southern Manufacturing 2013

Posted 8 years ago

Loctite engineering adhesives used in premium domestic stoves

Posted 8 years ago

Henkel helps Ford create stronger joints in engine parts

Posted 8 years ago

Non-hazardous engineering adhesives: no price premium

Posted 8 years ago

Improved low-bloom and low-odour instant adhesives from Henkel

Posted 8 years ago

Loctite anaerobic adhesives help bring in the harvest

Posted 8 years ago

Loctite 3090 instant adhesive fills gaps of up to 5mm

Posted 8 years ago

Loctite adhesives deliver the required safety standards

Posted 8 years ago

Loctite adhesives are temperature resistant to 120 degrees C

Posted 8 years ago

Comprehensive cleaning product range from Henkel

Posted 8 years ago

More bonding developments from Henkel with Loctite

Posted 8 years ago

Instant adhesives are temperature resistant to 120 degrees C

Posted 8 years ago

Free Loctite Industrial Selector Chart for maintenance products

Posted 9 years ago

Multan bactericide-free cutting fluids are cleaner and safer

Posted 9 years ago

Henkel features bactericide-free cutting fluid at MACH 2012

Posted 9 years ago

Improved threadlocking adhesives are more oil-tolerant

Posted 11 years ago

More applications