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Quality tooling is a fundamental requirement for the manufacture of composite parts. This is due to the fact that every step in the composite part manufacturing process must be tightly controlled to ensure superior material properties and predictable performance in the final product. This Composite Tooling Design program explores the composite materials used for tooling, and tooling design.

Die casting is a high precision, rapid parts-production process involving the high pressure injection of molten metal into a die having a cavity of the desired part shape. This program explores the common die cast metals and their various properties, as well as die casting machines and die cast tooling.

This program is part of the Fundamentals of Geometric Dimensioning and Tolerancing package. In Feature Relationships, the ten remaining geometric characteristic symbols and their categories (profile symbols, orientation symbols, location symbols, and runout symbols) are examined in greater detail using demonstrative examples to clarify their use.

The injection mold is an extremely important element of any plastic injection molding operation. Molds determine the shape of the part, vent trapped air or gases during injection, act as heat exchangers to solidify the molten plastic, and eject the cooled parts. This Plastic Injection Molds program highlights the primary injection mold components, including the mold base, cavity and cores, runner system, cooling system, and ejector system. This program also features segments on injection mold types, the use of computer simulation, mold prototyping techniques, and mold maintenance & repair.

The Thermoforming Process Components segment explores the materials, clamping systems, heating systems, thermoforming mold types, forming forces, and trimming processes. The basic thermoforming methods are also examined, including: drape thermoforming, cavity thermoforming, pressure thermoforming, plug assist thermoforming, and twin sheet thermoforming.

This Breakthrough Kaizen Events program shows an actual kaizen event at the Lantech Corp. where a total of more than 100 improvements were completed. Several new devices are demonstrated so the viewer can understand how the changes improved the process. See how they use a kaizen newspaper to keep everyone informed of any changes that are being made.

Design for manufacture and assembly (DFMA) is a proven design methodology used to optimize part costs and quality, while reducing time-to-market development. Part of the award-winning Manufacturing Insights Video Series, this program features an interview with Nicholas Dewhurst of Boothroyd Dewhurst. He explains the concepts and use of DFMA in product analysis to understand the drivers of cost, and the interaction of the individual pieces within the product to optimize design, manufacturability, and assembly.

This Fastening and Assembly program focuses on the primary fasteners and assembly processes used and includes sections on mechanical fastening, adhesive bonding, and automated assembly.

In the Investment Casting segment, Express Pattern and Barron Industries are highlighted to see how rapid prototyping accelerates investment casting prototypes, processes and production.

This program begins with an introduction to the basic elements of all paint formulations including pigments, additives, solvents, and resins. Viscosity and volatile organic compounds (VOC) are also explained. The two types of resin polymer structures, enamels and lacquers, are explained with an emphasis on the crosslinking aspect of enamels.