Metro Plastics Technologies - The Emphasis is on 'Solutions'
By Kym Conis (Plastics Business winter 2007 article) (Page: 1 2 3 4)
Advancing with Rapid Prototyping
One area in which Metro Plastics stands out from many other contract molders is with its rapid prototyping capabilities - a bold venture entered into nearly twenty years ago, which has become a major profit center today. In 1989, Metro Plastics purchased its first Stereolithography (SLA) machine when the process was very new and consequently, quite inconsistent. "The part data was not reliable and the machine did not always produce a good model," explains Hahn. "In those days, we didn't talk much about the process. If we made a good SLA part, we gave it to our customer. If it didn't turn out so well, we used the model for our own personal R&D and from it, were able to make suggestions to the customer." Metro had the foresight to visualize the potential of the SLA process back when few, if any, other molders recognized its value. "As far as we know, Metro was the first custom molder in the U.S. to install the system," states Hahn.
Being first in the door has had its benefits - for both Metro Plastics and its customers alike. "We went through the very early stages on how to manipulate the files. Our people are very skilled at this, as we started from the ground up with an infant process and grew with it," Hahn explains. The three-dimensional process is an additive process, which builds layer upon layer to create a functional mold, made of either silicone or urethane.
Over time, the technology improved and Metro was able to turn its prototyping capabilities into a profit center, as well as a benefit to its customers. Metro now has a division that is dedicated to rapid prototyping - building SLA models and casting urethane parts for design review, as well as part testing for hundreds of clients throughout the country. Metro's unique prototype lab is staffed with an experienced team of industrial designers and engineers who work with its customers to transform their concepts into products. Utilizing the latest in computer solids modeling software and laser modeling technology, Metro is able to test and prove the concepts before manufacturing begins. Metro's rapid prototyping bureau can transform a customer's product idea into a visual image and model, suitable for styling evaluation, preliminary design approvals, and part and tool design verification.
With its five SLA machines, Metro's rapid prototyping bureau constructs models for a variety of industries - from automotive and medical to aerospace and just about everything in between. Metro also is able to grow fine detail parts on its Viper machine using a small beam diameter of .004" and .001" layer in thickness. Metro's larger machines produce models up to 20" cube. These models then can be bonded and used as patterns for Silicone molds. "We can, and have, cast urethane parts as large as golf carts in one piece," says Hahn.
Metro's rapid prototyping capabilities allow the company to be involved in the early stages of a product, whether domestically or overseas. "Even if a product is high volume and goes overseas, we still have the opportunity to participate in the initial stages," states Hahn. From custom molders to OEMs, the rapid prototyping bureau offers a valuable advantage: the ability to see potential problems before making the tool. Even OEMs with prototyping capabilities utilize Metro due to the company's advanced capabilities. "When you need rapid prototyping, you need it today... not in a week. We can always get it done in time because we have the capacity," says Hahn.
Keeping the rapid prototyping side of the business as a separate division is important to maintaining the trust that other custom molders place in outsourcing prototypes with another molder. "We service our competitors and they have to feel confident in sending their prototypes to us," explains Hahn. "Once a client is introduced to the technology, he is spoiled and would not consider doing another project without having a SLA model or casting to test before starting the tooling process." If Metro is awarded a tooling and molding program, it provides the SLA models to its customers at a reduced cost or at no charge. "The value to both our customers and to Metro far exceeds the cost to provide the models."
