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Mobilarm is using low-pressure moulding with Macromelt to replace a previously subcontracted service. The company, which manufactures man-overboard rescue systems for the marine industry, brought Macromelt moulding in house to save subcontract costs, reduce scrap rates and introduce flexibility into its manufacturing and prototyping processes.

Mobilarm manufactures the Sea Marshall range of maritime survivor locating devices. Until recently, the company was subcontracting its requirement to encapsulate part of the aerial unit on the Sea Marshall system. A small cable connects to a PCB that features side-firing light-emitting diodes (LEDs). Part of the configuration is a delicate antenna spring that requires encapsulation.

The previous supplier produced overmoulds using a conventional injection-moulding technique, but the results were unsatisfactory. Fall-out rates for the cable were hitting 40 per cent, which was deemed unacceptable.

Mobilarm contacted Engineering Solution, which, through its partnership with Henkel, provides manufacturers 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 and is described as non-aggressive, highly cost effective and fast.

Key benefits of product application

  • The company’s failure rate has dropped to one per cent since the system’s installation 18 months ago; Ian Pinder, production manager at Mobilarm Europe, said this failure typically results from a PCB failure or bad joint in manufacturing.
  • The cycle time is around 30 seconds in jet with a further 30 seconds required for cooling — superior to traditional potting methods.
  • Pinder said the system has more than paid for itself already, saving the cost of subcontracting and eliminating the 40 per cent fall-out rate.
  • He concluded that the Macromelt system is quick and cost effective, aiding a far easier prototype phase, and supports excellent flexibility in manufacture.

Henkel is the world market leader in state-of-the-art industrial adhesives, sealants and surface treatment products for a wide variety of engineering applications. Its leading brands for the industrial market are Loctite, Bonderite, Teroson, Aquence and Technomelt.

Strong customer focus, research and innovation, consistent quality and sustainable business practices have contributed to its record of success, as has continuous improvement in both its products and methods of manufacture.

The company applies its expertise to the entire value chain across the engineering sector. Whatever you build, manufacture, assemble or repair, its technical consultancy service will provide all the assistance and training you need to ensure you have the best product and the skill to apply to its best advantage.

Henkel brands are internationally renowned for their proven reliability and performance and the scope of the company’s product programme extends from cleaning and pre-treatment through to bonding, sealing, filling and protecting, coating and lubricating. 

Henkel is the only adhesive manufacturer to offer a comprehensive range of products that are hazard-label free. Its Loctite Health and Safety series is suitable for the lion’s share of engineering applications and includes thread lockers, thread sealants, gasketing adhesives, retaining compounds and instant adhesives.

As both the product and its method of application dictate the quality of process, Henkel also has considerable expertise in the supply of dedicated dispensing equipment that, if necessary, can be bespoke to the application. This equipment ensures the product is applied quickly, cleanly, accurately and economically.

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