VERICUT User: Tri-Mack Plastics Manufacturing Corp.
By Sherry L. Baranek
When Tri-Mack Plastics Manufacturing Corp. (Bristol, RI)—a manufacturer of high-performance components for critical applications primarily for the aerospace industry—was looking for the least expensive way to cut leadtimes, verify cutter paths, and virtually inspect their cut parts, all without sacrificing quality, the company turned to CGTech/VERICUT software (Irvine, CA) to accomplish these goals. Fortunately, this software also helped Tri-Mack win GE Aviation’s Supplier Quality Awareness Award (see Flying High Below).
Beyond Moldmaking
Founded in 1974, Tri-Mack Plastics Manufacturing Corp. (Bristol, RI) first supplied machined PTFE-based components, such as bushings and piston rings, to the aerospace industry. Driven by customer requirements, the company expanded into other high-temperature thermoplastics. By 1980, the company added its first injection molding machines as well as moldmaking equipment.
Today, the company has evolved into manufacturing high-performance components and assemblies. In addition to toolmaking and injection molding, the company has a broad range of capabilities—including precision CNC machining, bonding and assembly, and engineering services. “Tri-Mack specializes in the high-temperature and highly-filled thermoplastics, such as PEEK, Torlon, Ultem, Ryton, Amodel and Nylon,” notes Rob Matrone, Director of Engineering for Tri-Mack. “More than just a molder, we partner with our customers to solve problems.”
Tri-Mack typically builds molds that are a cross between SPI 101 and 102 class molds, Matrone explains. “Although part volumes are typically low, the filled engineering resins processed and tolerances required, warrant hard tool steel, guided ejection, wear pads, and excellent heating and cooling with good temperature control. The majority of our tooling is for the aerospace industry, but we also support accounts in chemical processing, energy, medical and industrial equipment.”
Conquering Challenges
 | Typical tool tolerances for molding areas are +/-.0005, Matrone continues, and mold finishes vary from high polish mirror finishes to any of the standard EDM finishes—depending on the article drawing specifications. With time an issue, the company wanted to add lights-out machining capabilities. “We needed to run CNC machines unattended, so work could continue overnight as well as on the weekends,” Matrone comments. “Historically, we wouldn’t trust our cycles to run unattended. In the past, we would take even more time by CNC cutting wax before machining a workpiece that had substantial value already added. |
| CGTech/VERICUT software features many inspection tools so the user can view and analyze the geometry of the cut part. Models can be cross-sectioned multiple times at any orientation to check areas that would be impossible to see in a solid model (such as the intersection of drilled holes). Photos courtesy of CGTech/VERICUT. |
| VERICUT includes many inspection tools to view and analyze the geometry of the cut part. Models can be cross-sectioned multiple times at any orientation to check areas that would be impossible to see in a solid model (such as the intersection of drilled holes). The software has tools to measure thickness, volume, depth, gaps, distances, angles, hole diameters, tapping features, corner radii, scallop height, and edges. Delta X, Y, Z component distance measurements are |  |
| Tri-Mack Plastics Manufacturing Corp. Director of Engineering Rob Matrone with a mold that was simulated using CGTech/VERICUT software. |
| Cost-Competitive Tooling with Shorter Leadtimes Challenge Solution Results |
| Flying High Tri-Mack Plastics Manufacturing Corp recently received GE Aviation’s Supplier Quality Awareness Award, which recognizes high standards for productivity and quality. According to Tri-Mack’s Director of Sales Tom Kneath, the company was recognized for its support of the GENX-1B engine, which will power the new Boeing 787. “Tri-Mack produced six different complex injection molds and components on a very accelerated schedule,” Kneath explains. “Vericut played a key role in this process as we were able to keep our CNC machines running around the clock—producing hundreds of mold components in record time.” Tri-Mack worked concurrently with GE to optimize part designs for producibility and overall cost-effectiveness, Kneath continues. “Our tool design for the project used proprietary hand loads to mold complex geometry, including molded in-place metal inserts,” Kneath notes. “We also employed advanced selective laser sintering technology in our strategy to save time in the development process.” “We are very proud to receive this award,” adds Tri-Mack Vice President of Operations William Kain. “Like GE Aviation, we strive every day to meet or beat all of our customers’ requirements with high quality, high performance materials, processes and products. An award like this is confirmation we are meeting our goals.”
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