Wheeling, Ill.-based Dynomax Inc. plans during 2012's first quarter to boost its capacity to process thermoset and fluorosilicone resins, with three new Arburg injection molding machines: two 110-ton electrics and one 28-ton hydraulic.
Dynomax is making a “strong push into medical” molding and toolmaking, said business development director Mark Zic. Currently, the company is doing some small runs in the medical market, Zic said.
The firm budgeted about $5 million for capital investments this year, roughly the same as in 2010, but it did not disclose financial details of the equipment investment.
Dynomax operates 13 hydraulic and seven electric presses with clamping forces from 38-110 tons, shot sizes of 0.6-7.6 ounces and various vertical and horizontal configurations. Most are Arburgs, but the firm runs a few Engels. Six presses were added in late 2010, three with integrated Fanuc robotics and one with a microinjection unit. Dynomax lacks clean room capability but said it will invest as needs dictate.
Last year, aerospace and defense work accounted for about 60 percent of the company's sales.
In April 2010, Dynomax moved its headquarters to a new location in Wheeling from a Mundelein, Ill., facility that uses the space for additional plastics processing and mold making. Dynomax has other operations in Lincolnshire and Buffalo Grove, Ill.
The four facilities in northern suburbs of Chicago are located within 11 miles of each other. Total space is about 200,000 square feet.
The Mundelein site uses about 12,000 square feet for injection molding with 16 employees, and 8,000 square feet for toolmaking with 12 workers. Mundelein also handles related planning, engineering, inspection, assembly and machining functions.
The plant manufactures and assembles parts that may require high-precision tolerances down to plus or minus 0.0002 inch. Micromolding accounts for about 75 percent of the firm's plastics processing.
Parts include grommets and brackets for cable and harness management, specialty aircraft interior components and interconnect-system devices. Dynomax uses highly engineered resins including epoxies that may reach 540° F during processing and post-curing stages.
Pick-and-place Fanuc robots insert metallic pieces, and other Fanuc systems pull difficult-to-release silicone parts from hot-runner molds and then cut them apart.
Dynomax uses electrical-discharge-machining and computer-numerical-control tools to make hardened steel molds for in-house injection and insert-molding requirements and, as requested, for other processors.
Dynomax was established in 1986 with in-house plastics processing and mold-making capabilities from the start.
Eagle Registrations Inc. of Dayton, Ohio, audited and, in September, certified Dynomax under revision C to AS9100, the quality management system standard for the aviation, space and defense industries. Designation as a certified supplier simplifies the production and delivery process for customers in those industries and opens doors to potential new business. The company also is certified under ISO 9001 QMS and registered under International Traffic in Arms Regulations.
Aviation and defense customers include Raytheon Co.'s missile systems segment in Tucson, Ariz.; B/E Aerospace Inc.'s first-class seating unit in Miami; Boeing Co.'s commercial airplanes segment in Everett, Wash.; and two Bombardier Inc. operations — the aerospace division in Dorval, Quebec, and business jet subsidiary Learjet in Wichita, Kan.
With military expenditures beginning to slow, Dynomax is experiencing its fastest growth in the civilian aviation market including business jets.
Dynomax, which is family-owned and operated, employs 204 — about one-half of whom came aboard in the past two years.
Company founder Richard Zic is CEO, and his wife, Maura, is chief financial officer. Sons in key positions are Walter Zic, vice president of operations, and Mark Zic.
In furthering its medical effort, Dynomax will exhibit at UBM Canon's Medical Design & Manufacturing West trade show Feb. 13-16 in Anaheim, Calif.