DESMA helps customer revolutionize part production to achieve FOUR times throughput
“Our partnership with DESMA has revolutionized the way we run parts in medium to high volume activities.” - Precision Associates
Precision Associates, for over half a century, has been a leading manufacturer of top quality, custom rubber seals and other rubber products for a variety of markets. Their capabilities include close-tolerance, precision machined plastic and metal components. From O-rings to U-cups to square gaskets, Precision Associates molds essentially every type of rubber seal you can think of.
For nearly 60 years, Precision Associates used the same traditional methods and machines for compression, transfer, and injection molding of rubber materials. Precision Associates’ engineering team recognized the need to modernize their equipment in order to open up a new range of capabilities and increase their efficiency. After looking at several options, they chose to partner with DESMA on their first new injection molding press in 2018.
Key Selection Factors for DESMA:
Ease of use - DESMA’s injection screw and plunger system uses a unique method to allow for cleaning and maintenance that Precision Associates found to be very quick and efficient
Ability to work with existing molds - At the time of partnership with DESMA, Precision Associates had over 8,000 active molds. Replacing those to adhere to a new platform would’ve been prohibitively expensive and a major roadblock. DESMA worked to modify their standard injection press allowing them to run their existing tools on that new press, which was a huge win!
Customization for the task - Repeatedly, DESMA has worked to customize their solutions to fit the unique needs of Precision Associates. The first run of HCR Silicone (Gum Stock) didn’t work well as the machines weren’t designed for that soft of a material. DESMA built a custom materials delivery system for Precision Associate’s press that provided a path for this new material to work. DESMA also worked with Precision Associates to get a machine running in their ISO Class 7 Clean Room for special medical applications.
Upon receiving and onboarding their first DESMA machine, Precision Associates found they were able to produce 4 times the throughput of their existing machines, and at half the labor cost! These results were so incredible, that in less than 3 years, Precision Associates has gone from 1 to 9 DESMA machines, and have revolutionized the way they run parts in medium to high volume activities.
Precision Associates has been able to bid competitively and win several large projects that they would’ve been unable to secure using their conventional molding method pre-DESMA machines. DESMA machines have also enhanced their work on existing high volume projects by cutting labor which decreases costs for both Precisions Associates and their clients, while reducing the need for long overnight and overtime hours for their team.
DESMA continues to support Precision Associates with strong support, solid training procedures, and a partnership approach to work on custom needs as they arise. It's been a great success and a foundation has been laid for more machines and a long term relationship moving forward.
DESMA Automation - Full Turnkey Support
Investing in automation technology will improve molding quality and maximize efficiencies.
For the last few decades in the elastomer molding industry, there has been an increasing demand to introduce automation principles into typical molding operations to improve efficiency and eliminate traditional manual labor. In the late 1990s DESMA recognized this trend in the industry & began investing in complete turnkey support infrastructure for our customer base.
From initial concept support to final implementation & installation, our Project Engineering divisions located in the USA, Europe, and Asia have the resources available to manage projects of automated systems for even the most demanding molding operations.
Some of the more basic examples of automation include basic brush systems & mold plate manipulating technology. Single side shuttle tables, centerplate exchange systems, and sliding heating platen technology are examples of this basic automation. An investment in these technologies will improve molding quality & ergonomics, maximize efficiencies, and eliminate labor operations.
More advanced automation projects often include multi-axis robots, customized pick and place systems, automated trimming devices, and even conveyor transport technology. Our full-time project engineering staff located in Hebron, Kentucky can customize a solution specific to our customers’ needs. For each project, we do an in-depth analysis of the goals based on the technical requirements while also keeping in mind economical constraints that may be present. Once we have collaborated with the customer to share information, a tailored Project Analysis is then presented to the customer for their consideration.
In rubber, each automated project is unique. For a percentage of our projects, a customer acceptance runoff (or Factory Acceptance Test) occurs at our World Headquarters in Germany after the new injection machine is manufactured. For other domestic projects, this acceptance runoff takes place at DESMA USA in Hebron, KY - or in more basic scenarios, the runoff and acceptance can be executed when the press is delivered to the customer location. The acceptance runoff tests, system optimization, and in-depth training are the final steps to the implementation of our turnkey automated molding cells for our customers.
If you are interested in automating your rubber or silicone molding application, please contact us at sales.us@ to discuss your specific project goals and how DESMA can support you. desma.biz
Employee Milestone - 27 years at DESMA!
Today we honor a special employee milestone! This month Scott Early, President of DESMA USA, celebrates 27 years with the company.
From his start in sales engineering to the role of President, his dedication to DESMA has been there from the beginning. Scott’s commitment and drive to push DESMA USA to be a better and stronger business is a key to company success. Our Hebron facility shares the team-building spirit and customer care drive that makes us a primary supplier for rubber and silicone injection molding.
Vacuum in the Rubber Injection Molding Process is Critical to Success
The importance of vacuum in rubber injection cannot be overstated.
Vacuum is an often used but a commonly misunderstood technique in rubber injection molding. The main purpose of vacuum is to remove air entrapments during the injection and vulcanization process that occurs once rubber is packed inside an injection mold. This sounds simple in theory but to achieve good vacuum in a repeatable injection process is a bit more complex.
Vacuum is achieved by evacuating air and developing gasses inside the mold or mold cavity prior to and during the injection process. A properly designed mold will have strategically located vacuum connections and dump grooves to assist cavity filling without voids in the product. Often these vacuum locations, or the vacuum achieved at these locations is insufficient, improperly designed or in many cases hindered by an inadequate working vacuum pump system outside the mold.
A "near perfect" vacuum is considered 0.996 bar or 29.4 mm hg. Many times this is difficult to achieve due to poorly sealed mold plates or is caused by a variety of other factors. Proper vacuum is a function of both sound machinery maintenance, vacuum pump and vacuum line maintenance as well as a properly sealed mold plate and cavity design. DESMA USA's NAMC division considers vacuum a key criteria in any new project design phase.
Another way to achieve adequate vacuum in rubber injection molding is to utilize a vacuum chamber where the mold is placed completely inside a controlled environment. To remove air, a properly sized vacuum pump with an accumulator tank evacuates the air completely within the chamber (versus cavity only) prior to or during injection. Special features within the hydraulic circuitry of the press must be incorporated in conjunction with vacuum for optimum process stability.
DESMA has many years of experience not only in process development using vacuum, but also in the development of machinery and molds that require vacuum. Our DESMA Trainer, Walter Frick, has decades of experience in this subject. Walter offers several classes on rubber processing that touch on vacuum. These classes were designed for in person instruction but have been updated and are now available online.
DESMA USA embraces Co-Op opportunities
DESMA understands that the next generation of employees starts now. Highly skilled and technically sound workers don’t just happen and DESMA USA is committed to improving the workforce by developing skilled young persons.
DESMA USA is cultivating the employee base by providing co-op opportunities to our tri-state area. DESMA USA currently has two new co-op positions in our engineering department and our NAMC (North American Manufacturing Center). Patrick and Dillon will learn from our knowledgeable and seasoned workforce in order to learn technical skills and master the arts of the rubber and silicone system.
DESFEED - The Flexible Silicone Feeding Solution
A stand alone feeding solution to compliment injection molding.
For applications which require the injection molding of silicone (HTV – High Temperature Vulcanization / HCR – Heat Cured Rubber) DESMA offers a flexible material feeding solution named DESFEED.
DESFEED is a stand-alone device which delivers the raw material to the screw of the elastomer injection machine where it is further processed and injected into an injection mold. Utilizing an electrically driven screw type positive displacement pump and a high pressure feeding hose, DESFEED takes the HCR/HTV raw material (blocks or “pigs”) and meters it to the opening of the injection unit screw.
DESFEED is truly unique in that it is a portable system which can easily be connected and disconnected from an injection machine.
To use, connect the electrical power to the unit, the feeding hose , and a signal plug to the injection machine and it is ready for operation. The ease of connection makes it possible to easily and quickly move one DESFEED unit between multiple rubber injection molding machines.
DESFEED is best suited for HCR / HTV materials with lower viscosity.
To learn more about this technology, please contact your DESMA Sales Engineer.
Happy New Year from DESMA USA
Looking forward, DESMA is taking the long view on North American manufacturing. We are strategically investing in people, equipment, and product development. We believe that 2021 will be a year of robust economic recovery.
When I reflect back on 2020, I am proud that we provided uninterrupted support to our customers during Covid. This was due to our dedicated staff, supply chain management and modern IT infrastructure. DESMA Customer Care continued with machine, tooling, equipment installation and warranty service. Digital products like RemoS, SmartWall and SmartConnect are now being used extensively in lieu of in person visits.
A highlight of 2020 is our remodeled office facility at DESMA USA in Hebron, KY. Updates to our redesigned space include new engineering offices, Customer Care Center, NAMC Tooling design area plus new meeting spaces. Our 9,500 sq. ft. (883 sq. m.) remodeled office fosters employee collaboration using shared spaces and innovative technology. This project was an investment in DESMA's future and demonstrates our commitment to the North American market.
To connect with customers DESMA hosted a virtual open house called the XpertenForum 2020. Thousands of people logged on as we presented automation concepts, machine networking solutions and DESMA product content. The open house complimented training webinars that we hosted throughout 2020 which were met with strong interest. Look for additional webinars in 2021 on topics like elastomer processing, DESMA preventive maintenance and DESMA tooling.
Indeed 2020 changed the way that DESMA interacts with customers and colleagues around the globe. Change is good and challenge inspires creativity!
During my career I have observed that capital equipment tends to lead economic cycles both in times of slowdown and conversely in periods of growth. Over the last few months, we are seeing green shoots in the North American market. These green shoots give us reasons to be optimistic in 2021 and beyond.
Wishing you, your business, your family and loved ones a healthy and Happy New Year!
President & CEO | DESMA USA, Inc.
Servo package now available for DESMA Alpha and Sigma Machines.
Improve energy consumption, reduce noise, optimize flow and enhance speed control with a Servo package.
To complement our award winning ServoGear system for our DESMA 968 and 969 press series DESMA is now offering an energy saving Servo package option in their Alpha and Sigma injection machine model presses. DESMA uses system matched pumps, drives and controllers sourced from Bosch Rexroth are mated to the DRC 1030 control system.
By incorporating a Servo electric drive into the hydraulics system, improvements in our Alpha and Sigma series machines can be seen across the board in areas relating to noise reduction, optimized flow and speed control for press movements, and of course energy consumption. With a Servo option, DESMA uses just one high capacity axial piston pump. This pump can work at two different settings & output configurations depending on the flow requirement during individual press movements throughout the molding cycle. For example, during high flow requirement when pressure and force requirement is low (like for an ejector movement), the pump operates in the high flow range. Transposed, when pressure requirement for the injection machine is high (like for clamping force & injection process holding pressure), the pump works at low delivery capacity for fluid. So, for each movement, the hydraulics can be tailored to the specific hydraulic function taking place at any given time. The ability to control the hydraulics in this manner leads to additional power savings.
The defined amount of energy savings the Servo option will generate is variable depending on many factors relating to press operation & the customers determined molding process. These variables include the required cure time for the parts in addition to the number and length of machine hydraulic movements required within each cycle. It is estimated that with optimal conditions, this Servo option can save up to 36% of overall injection machine power consumption when compared to a standard proportional hydraulics system.
To learn more about this technology, please contact your DESMA Sales Engineer or email us at sales.us@. desma.biz
DEMONSTRATION LAB COORDINATOR
DESMA USA would like to congratulate Ricardo Valdivia as he moves into his new role as Demo Area Coordinator.
Ricardo has been with DESMA for over 10 years and is an integral part of the Engineering Team. Ricardo’s new role will incorporate the responsibility related to runoffs and procedures in the demo area. He will also collaborate with our Customer Care Department to head a curriculum for new service technicians when they arrive at DESMA USA for training. This new layer of organization provides assistance to our ever growing in-house services that compliment NAMC (North American Manufacturing Center) and our demonstration lab in Hebron, KY.
DESMA SmartFlow for optimal mold design
Proprietary DESMA software enhances mold designs
SmartFlow software and analysis is unique to DESMA due to material characterization and injection unit data incorporated in mold flow calculations.
Traditional mold designs try to keep cavity numbers even, runners symmetrical and equal in length to give molds the best shot at optimal balance from the start. However, there are certain instances in which our design team will be tasked with designing a mold with an odd number of cavities, or an odd number of decks, and sometimes the article itself has an odd shape that doesn’t lend itself very well to packing out completely with elastomer during part injection. Balancing an odd number of cavities is always a challenge.
In these instances DESMA utilizes our SmartFlow software in order to prove out the mold design concept and catch any issues that the flow analysis model data may illustrate. SmartFlow calculations may prove the design concept immediately. The data from SmartFlow could also indicate the need to increase the size of the runners or the gate depth, decrease the amount of runners, or which locations to add vents to prevent air entrapment during article injection. DESMA uses SmartFlow analysis data to lead the way to optimize the mold design during the CAD phase. Catching issues in the CAD phase is always the most cost effective method before cutting anything into steel. Optimizing the mold by using this data leads our customers to a more broad process engineering envelope throughout the life of the mold.
The SmartFlow analysis process starts with our design engineers creating a complete 3D mold in Siemens NX software. Additionally, our designers will create a complete elastomer model that includes everything from point of injection through sprue, runners, gates and ultimately completely filled articles and overflow grooves. We then export this NX 3D model to a raw CAD data file to be imported into our mold flow analysis software. The SmartFlow engineer will then assign a material to the elastomer from our material library. Additionally, we can even send customers supplied material for chemical analysis to assign the exact formula the customer is running to the elastomer model. Our SmartFlow engineer will then set a running temperature gradient to the mold, set the software and run hundreds of injection simulation cycles. Using this data engineers then fine tune the design and run the simulation cycles again until satisfactory results are achieved.
Do you have a mold design that you think may be a good candidate for DESMA SmartFlow and analysis? Contact DESMA and see how we can help! namc.us@ desma.biz
DIRECTOR OF SALES ANNOUNCED AT DESMA USA
We are pleased to congratulate Marc Vonderlage as the Director of Sales at DESMA USA.
Transitioning from his role as Regional Sales Engineer, Marc will now head the sales division creating and fostering sales opportunities. Rest assured though - the DESMA team is still the same and you can count on the same faces to serve and assist you!
New Products & Services at our DESMA Company Showcase!
- Machinery Options, Tooling Capabilities, Automation Systems and Digital Services
- Register for the ExpertForum2020
- Schedule a DESMA Virtual Tour
- Set up Meetings & Appointments with DESMA industry experts
The annual International Elastomer Conference and Expo is the rubber and silicone industries yearly event where our customers and suppliers come together. Since we can't meet in person at the expo, DESMA will be featured in the IEC Company Showcase featuring a wide variety of DESMA equipment, tooling capabilities (NAMC), automation options and other digital services and products we offer.
Visit our Company Showcase to learn all about DESMA equipment, new technology and turnkey solution. Take a virtual tour or book an appointment with a DESMA representative all in one place!
DESMA FIFO-A | Flexibility for Strip Fed Material
October, 2020 (Hebron, KY) Flexibility for strip fed material plus silicone applications.
Klockner DESMA Elastomertechnic builds a variety of First-In First-Out injection units to suit different material and process requirements within the elastomer molding industry. These different types include FIFO-A, FIFO-B, FIFO-C, and FIFO-K, each of which are designed for a specific purpose.
Of the options available from DESMA, the “FIFO-A” injection unit is our most popular and most flexible.
The “FIFO-A” injection unit is designed specifically for use with vertical clamping machines in a variety of injection volumes ranging from 85 ccm up to 22,900 ccm.
One very attractive characteristic of the FIFO-A concept is the ability for the end user to change between different material types.
The most common use of this injection unit is for processing strip type raw materials such as NBR/SBR, HNBR, FKM, Neoprene, AEM and others. However it is also quite easy to include the ability of processing HCR silicone materials by including a silicone stuffer. The addition of a stuffer to the FIFO-A injection unit can be done so that switching the machine between HCR operation and strip material operation is simple; requiring only hand tools and no more than 30 minutes.
Connecting the silicone stuffer requires only the removal of the strip guiding device and installation of a connection pipe between the stuffer output and screw input.
Surprisingly, the same FIFO-A injection unit that is used for highly viscous materials such as HNBR can also effectively be deployed in applications to inject liquid silicone (LSR). While the conversion from strip material to LSR is more involved than connecting a silicone stuffer, the process remains straightforward. The conversion requires the exchange of the screw cylinder, injection plunger, and the addition of a LSR meter / mix system including a 2-pass static mixer.
The ability to process a wide variety of materials with the same basic injection unit provides our customers the ability to pursue business in a wide variety of markets and applications.
By combining the capabilities of the FIFO-A injection unit together and selecting the optimal process type (hot or cold runner direct injection, hot or cold pot injection transfer, or injection compression) nearly all elastomer molding challenges can be met.
For more information on DESMA FIFO availability and equipment options contact info.us@. desma.biz
Take a virtual tour of DESMA USA!
See what is new at DESMA USA!
DESMA USA recently completed building renovations. This included modernizing our conference rooms and an upgraded Customer Care Center! Please come see our new space, tour our demonstration lab and visit the NAMC (North American Manufacturing Center) where we produce tooling and provide turn key systems to the rubber and silicone industry!
Continuously Committed - DESMA Remote Support & Customer Service
September, 2020 (Hebron, KY) Digital Service provides quick machine diagnosis.
DESMA USA is committed to the support of our customers. The Digital Services division of DESMA USA has options to quickly and safely connect your machine to our USA based team of experts.
Traditionally, the only way to obtain any kind of customer support was via telephone or to have a service technician visit the customer's facility. DESMA USA is able to provide remote support without leaving our Hebron headquarters, which is critical now when onsite customer visits are at a minimum and strategic safety measures are in place at manufacturing facilities.
Utilizing DESMA's REMOS | SmartWall technology a service technician can remotely connect, diagnose and help provide high level technical support plus offer online solutions in real time.
- REMOS is a portable customer support tool that connects via Wi-Fi or GSM cellular network. This means that it can be moved between multiple DESMA machines at the same facility.
- SmartWall operates on hardwired lines into one specific machine and uses the company's internet connection via an Ethernet cable.
Once either of these units are installed, a DESMA service technician can go online, monitor and view the machine screen at any time. These options allows DESMA to monitor your machine I/O cards, control voltages ad check machine settings without having to wait for travel time. These tools provide great options for diagnosing many common machine issues and are a valuable investment in keeping production flowing.
For further information regarding REMOS, SmartWall or our digital services contact DESMA at firstname.lastname@example.org
Rubber and Silicone Molding Solutions
August 5, 2020 (Hebron, KY, USA) DESMA is thankful to be able to contribute molding solutions in the US market during the COVID-19 crisis. As an example of this work is a recent partnership and sale of equipment to a company involved in the manufacturing of medical industry and safety respirators.
DESMA aided this customer by refreshing an aging installed machine base. The older injection molding machines were plagued with reliability issues and outdated electrical controls. Maintaining very tight tolerances and stringent quality requirements on their molded products required the investments.
Their new DESMA machine has evolved technology such as the fully hydraulic Benchmark clamping unit design with superior clamping force distribution and an ergonomically low working height. It also includes a hi-resolution, trend based control system called the DESMA DRC 2030 TBD. This new control system has a large 24” touch screen display with control data and settings consolidated on one screen page allowing for easier parameter adjustments. The control system includes process data acquisition with trend graphics as well as network capability with DESMA’s Smart Connect device. This new technology was announced at the K-Fair in Dusseldorf in the fall of 2019 and is now in full production. The new control system is designed for IoT connectivity, for greater integrations and remote support.
For more information, contact our engineering and sales staff at Sales.us@ desma.biz
DESMA Continues to Serve Critical Infrastructure
July 20, 2020 (Hebron, KY, USA)
DESMA continues to serve critical industry infrastructure such as military and aerospace. As an essential supplier manufacturer of rubber and silicone injection molding machines, DESMA’s technology is applicable for the production of U.S. military and aerospace grade electronic shielding solutions. For years DESMA has delivered systems that mold gaskets and seals designed to protect against Electromagnetic interference (EMI) in addition to vibration, heat and shock. Products molded on DESMA machines are used in military tank, naval and aircraft applications.
Conductive elastomer gaskets used for EMI shielding are often complex shapes with tight manufacturing tolerances. DESMA clamping units are ideal for such molding applications. Our machines are designed with pre-stressed, precision ground and surface hardened tie rods. DESMA clamp units use high grade metals for optimum parallelism. Even DESMA insulator boards are special designed for both thermal efficiency and high pressure resistance. DESMA’s are designed for years of repeatable performance under extreme conditions.
As some of the highest performing dielectric materials are suitable for injection, DESMA’s patented FIFO (first in – first out) injection technology is applicable for EMI article molding. Our injection units are capable of producing up to 3,500 Bar (51,450 PSI) injection pressure for direct injection applications. In addition, DESMA injection units, due to their homogeneous mixing and dosing capabilities are ideal for ITM (Injection Transfer Molding) molding of conductive elastomers.
DESMA USA has a modern 33,000 sq foot facility located in Hebron Kentucky (greater Cincinnati area). DESMA 968 series machines are available for EMI material trials ranging in size from 100 tons in clamp force up to 700 tons with FIFO injection shot volumes up to 6.0 Liters (approximately 15 pounds of shot). To facilitate mold trials, DESMA’s North American Manufacturing Center (NAMC) also located in the Hebron facility can modify existing tooling for molding trials if required. DESMA continues to serve manufacturing sectors such as military and aerospace. For more information, contact our engineering and sales staff at Sales.email@example.com
DESMA USA COVID-19 Update - July 2020
FOR RELEASE JULY 15, 2020 (Cincinnati, OH)
DESMA is thankful to give a good report and update during the continuing COVID-19 situation. First of all, the health, safety, and protection of DESMA customers and employees is our highest priority. Our team is fully staffed with essential team members for production, engineering, operations, and support are working at the facilities under compliant safety protocols. Other team members continue to work remote and virtually. DESMA is operating at full capacity, remains strong, and continues to serve the industry.
Business continuity planning includes monitoring the situation and adjusting as needed with proactive measures to minimize any disruption. DESMA is proud to support and contribute to COVID-19 related initiatives as we serve manufacturing in health science related areas.
DESMA has made several modifications and improvements in our facilities to ensure the safety protocols are being followed in allowing building and production to continue in a safe way, including a previously scheduled remodeling. The DESMA leadership team has made contingency plans to continue production in a safe and compliant manner in consideration of unknown future events. DESMA is able to accommodate visitors with advance planning and some limitations to maintain protocols.
DESMA is meeting all production timelines, fulfilling all orders, and we continue to supply a sizable spare parts stock that remains available. DESMA USA Support Services system continues to be staffed. We can be reached at 1-859-372-3399 as well as via e-mail at Parts.firstname.lastname@example.org, Customercare.email@example.com and Service.firstname.lastname@example.org. We are configured and staffed to operate both remotely and with limited employees on our premises to support you. Our field service technicians have VPN access to our network that enable customer support via telephone, Remos, SmartWall and other service platforms. Our Regional Sales Engineers remain available to plan and consult with you at this time. Project development and mold inquiries along with service support concerns will continue to be handled without interruption.
If there is a machine need, engineering support, technical support, or advice and consult from one of our team of experts, we are here to continue to serve. We hope you and your loved ones continue to stay safe and healthy, and we are thankful for your support.
Scott Early | President & CEO
DESMA USA, Inc.