Mold-A-Matic Corporation
R-S-009 Rev. C
AN ISO 9001 / QS 9000 CERTIFIED COMPANY
MAMCO
Precision Moldings
1

Mold-A-Matic Corporation
R-S-009 Rev. C
Specialists in Insert Molding
Automatic loading systems, reel to reel molding, standard shuttle and rotary molding machines.
Program and Design Excellence
Program Management focused on early product development.
Focus
Managing total quality in all phases of our operation to achieve and exceed customer satisfaction and expectations.
Technological Systems in Place
Cad Design - Modem, Mold Flow Simulation, Molding Process
Control, SPC, JIT and EDI, Bar Coding, Full Automation
Systems
MAMCO
Precision Moldings
2

R-S-009 Rev. C
Mold-A-Matic Corporation
MAMCO
Precision Moldings
3

Mold-A-Matic Corporation
R-S-009 Rev. C
Incorporated in 1964, MAMCO (Mold-A-Matic Corporation) has grown to become an industry leader in the development, design, and manufacturing of precision custom molded components and assemblies.
As a producer of engineered molded parts and assemblies, MAMCO utilizes all grades of thermoplastics throughout their manufacturing process. MAMCO’s trained, motivated and dedicated employees are working three shifts, five days per week, within a 30,000 square foot facility with 32 molding presses ranging in size from 15 to 210 tons.
MAMCO’s first customers were in the potentiometer industry which required miniature, close tolerance, molded components. Today, MAMCO supplies the automotive, medical, consumer product, telecommunication, electronics, military and semi-conductor industries. With qualified engineering, quality and production professionals, MAMCO is able to embrace the concept of “Managing Total Quality” (MTQ) through concurrent engineering, continuous quality improvements and the guidance of our established ISO 9001 and QS 9000 standards.
MAMCO
Precision Moldings
4

Mold-A-Matic Corporation
R-S-009 Rev. C
is conveniently located in central New York between the cities of Binghamton and Albany on Interstate 88 and 20 miles South of Cooperstown, home of the Baseball Hall of Fame.
Albany
Syracuse
Binghamton
Cooperstown
Oneonta
New York City
MAMCO
Precision Moldings
5

Mold-A-Matic Corporation
R-S-009 Rev. C

Single source procurement for straight and insert molded components and assemblies.
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High quality, consistent repeatability, complex components and assemblies.
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Fully staffed, in-house engineering support.
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Sales management with emphasis on continuous customer support who understands the demands of the automotive, electronic, military, medical, telecommunications, computer and consumer product industries.
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A quality program based upon Zero Defects and Continuous
Improvement which emphasizes design for manufacturability, preventative engineering and advanced planning. This led to MAMCO’s ISO 9001 /QS 9000 certification.
MAMCO
Precision Moldings
6

Mold-A-Matic Corporation
R-S-009 Rev. C
12 MM USD
125
Aerospace
Automotive
Computer
Electronics
Medical
Military
Telecommunications
Consumer
Products
MAMCO
Precision Moldings
7

Mold-A-Matic Corporation
R-S-009 Rev. C
Aerospace
Computers
6%
2%
Telecom 7%
Military
4%
Electronics
19%
Medical
9%
Consumer
Products
8%
Automotive
45%
MAMCO
Precision Moldings
8

Mold-A-Matic Corporation
R-S-009 Rev. C
DELCO ELECTRONICS
VISTEON AUTOMOTIVE
MOUNTAIN MEDICAL
PHILLIPS AIRPAX
MCT
MALLORY CONTROLS
MOSLER
DURACELL
NCR CORPORATION
THOMAS & BETTS
SENSORMATIC
C & K COMPONENT
CTS
WARNER TECHNOLOGIES
HUGHES POWER PRODUCTS
TELEX CORPORATION
IBM
RAY-O-VAC
EXERGEN
TYCO
DELPHI / DELCO
TRW
TERADYNE CONNECTORS
ASPEN LABS
CLAROSTAT
DuPONT
PACKARD ELECTRIC
LITTON CORPORATION
EATON CORPORATION
HAMILTON DIGITAL
IRC
BREED TECHNOLOGIES
3M
BOURNS
AMPHENOL
MOTOROLA
ALLIANT TECHSYSTEMS
LOCKHEED MARTIN
GENERAL DYNAMICS
INVACARE CORPORATION
ASTROCOM ELECTRONICS
HARLEY DAVIDSON
UT AUTOMOTIVE
DUNCAN ELECTRONICS
CONMED
BURNDY
HONEYWELL
BECKMAN
BLACK & DECKER
GENERAL ELECTRIC
NEW ENGLAND INSTRUMENTS
ROCKWELL AUTOMOTIVE
CENTURY MANUFACTURING
TELEDYNE CORPORATION
DALE ELECTRONICS
BERG ELECTRONICS
CORNING, INC
VISHAY
AMP
SARGENT ART
QA TECHNOLOGIES
CHERRY AUTOMOTIVE
MAMCO
Precision Moldings
9

Mold-A-Matic Corporation
R-S-009 Rev. C
AB - ENGLAND
PHEH
SPECTROL
AB - GERMANY
RUF
VISHAY - ISRAEL
PHILIPS - HOLLAND
HELLA
VDO
BOURNS
MAMCO
Precision Moldings
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Mold-A-Matic Corporation
DELCO ELECTRONICS
UTA
ROCKWELL AUTOMOTIVE
BREED TECHNOLOGIES
EATON CORPORATION
AMP
BOURNS
DOMESTIC
TRW
DELPHI
VISTEON AUTOMOTIVE
DUNCAN ELECTRONICS
3M
CTS
DALE ELECTRONICS
ABROAD
AB - ENGLAND
HELLA
RUF
SPECTROL
AB - GERMANY
PHEH
VDO
BOURNS
R-S-009 Rev. C
MAMCO
Precision Moldings
11

Mold-A-Matic Corporation
PRECISION COMPONENTS
UTILIZED WITHIN:
ELECTRONIC DOOR CONTROLS
R-S-009 Rev. C
MULTI-FUNCTION SWITCHES
INSTRUMENT CLUSTER
COMPONENTS
(VISUAL AND NON-VISUAL)
THROTTLE
POSITIONING
SENSORS
TRANSMISSION
TEMPERATURE
SENSORS
SEAT BELT
COMPONENTS
POWER SEAT AND
HEAT SWITCHES
AIR BAG
SENSORS
AIR/FUEL
SWITCHES
HEAD LAMP
MAMCO
SWITCHES
Precision Moldings
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Mold-A-Matic Corporation
R-S-009 Rev. C
Engineered Solutions
Capabilities:
Original Designs Mold-Flow Analysis Design FMEA
Design Optimization Customer Process Integration Process FMEA
Advanced Quality Planning (APQP) Statistical Process Control Application Testing
Tooling
Capabilities:
Short Run Prototypes
High Speed, Precision Dies
Multi-Cavity Molds
Automated Assembly Systems
Semi or Fully Automation 100% Visual Inspection
Vision Systems Attribute Checking
Custom Testing
Tolerances: > .0005 In.
Automated Packaging
Moldings
Capabilities:
Material: All Engineering
Grades of Thermoplastics
Custom
Size: 1 Oz. to 4 Oz. 15 to 90 Ton
Inserts
13 Oz. 210 Ton
Capabilities:
Wire Brushes, Plastics,
Screw Machine Parts,
Castings, Varsities, Wire
Forms, Capacitors
Decorative Appliqués
Precision
Stampings
Capabilities:
Material:
Base to Precious and Bi-Metal
Capabilities:
Reel to Reel
Tube
Tray
Strips
Piece Parts, Bulk
Custom
Packaging
Ship to
Customer
Secondary
Operations
Secondary Operations:
Automation Systems
Post Mold
Operations
Hot Stamping
Pad Printing
Assemblies
Forms of Assembly :
Custom To Meet Your
Requirements
MAMCO
Precision Moldings
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R-S-009 Rev. C
Mold-A-Matic Corporation
The management and employees of Mold-A-Matic are committed to manufacturing products that conforms to customer requirements and specifications. This commitment is reflected in the following quality objectives:
 In the spirit of teamwork and cooperation with our customers, MAMCO will produce a quality product.
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MAMCO will maintain a formal quality system meeting and or exceeding all
QS 9000 quality system requirements.
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MAMCO will foster an atmosphere for continuous improvement in all phases of operations while focusing on our Zero Defects Program and PPM goals.
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MAMCO will communicate our quality policy and objectives to all employees.
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MAMCO will continue to develop relationships with our customers and supplier base that emphasizes continuous improvements.
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MAMCO will empower employees so they can help improve the systems that effect their work.
MAMCO
Precision Moldings
14

Mold-A-Matic Corporation
R-S-009 Rev. C
MAMCO has been actively involved with a Zero
Defects Program since 1981. Through this philosophy and world class manufacturing concepts, we are striving for perfection in every aspect of our business.
MAMCO’s commitment to “Managing Total
Quality” involves all MAMCO personnel. Our focus is to achieve total customer satisfaction through continuous quality improvements and gain preferred supplier status.
MAMCO will maintain and update our procedures as we work with new suggestions, methods and technologies associated with continuous improvements. This outline will be in accordance with QS 9000 specifications.
MAMCO
Precision Moldings
15

Mold-A-Matic Corporation
R-S-009 Rev. C
 MAMCO’s dimensional SPC procedures will facilitate process and capability improvements.
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MAMCO will track and maintain PPM levels with an ultimate goal of
Zero PPM for all customers.
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MAMCO will constantly work on all programs to establish automatic checks and systems to prevent the manufacture of visible and subjective discrepancies. This will be accomplished by utilizing at the process Vision Systems, Visual CMM equipment and custom testing automation.
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MAMCO has established a goal for having all of our suppliers certified to ship to stock and do so in accordance with QS9000 specifications.
 MAMCO is utilizing APQP and Design / Process FMEA’s to analyze potential failures, effects of failures, seriousness of failures, probability of occurrence and detection, current controls and will recommend an action plan based on these analysis.
MAMCO
Precision Moldings
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Mold-A-Matic Corporation
 New Mold Requirement Reports
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In-Process Cost of Quality
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Fallout Efficiency Reports
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PPM Reports
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Corrective and Preventive Procedures
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Non-Conforming Material Reports
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Discrepant Material Reports
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Internal Rejections
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Customer Complaints/Returns
 On-Time Delivery Monitoring
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Supplier Indexes based on:
 Quality

 Responsiveness
Delivery  Cost
R-S-009 Rev. C
MAMCO
Precision Moldings
17

Mold-A-Matic Corporation
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MAMCO uses the customers forms when supplied or our own 8d format.
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MAMCO uses CITI forms for internal improvements and corrections.
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MAMCO also provides our suppliers with a specific form to be completed for all discrepancies.
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Finally, MAMCO has our non-conforming material reports that drive corrective action on the production floor.
R-S-009 Rev. C
MAMCO
Precision Moldings
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Mold-A-Matic Corporation
Part Designer Molder Insert Mfg.
R-S-009 Rev. C
Time
Part Designer
Molder
Insert Molder
Time
The end result is a optimized part, designed for manufacturability , which will travel through the entire process in the least amount of time.
MAMCO embraces early involvement through concurrent engineering!
MAMCO
Precision Moldings
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Mold-A-Matic Corporation
(Injection Molding Process Simulation Software)
• Moldflow Part Adviser enables a quick evaluation of molded plastic parts for “manufacturability”.
R-S-009 Rev. C
• Moldflow Part Adviser provides reliable answers to key design questions in minutes, working directly from the CAD solid model.
•
Design concepts are quickly tested and modified at the early stage when the cost of change is minimal.
•
The Part Adviser provides advice on the confidence of fill, injection pressure, pressure drop, flow front temp, fill time, fill pattern, weld lines, and air traps. Results are printed in color plots and recorded in windows .avi animation files.
•
Produces results in minutes and displays them directly on the solid model.
•
Over 4000 materials in the Moldflow database.
( Mechanical Design Software)
• Creation of solid models.
•
Solidworks imports solid model files in XMT, IGES, STEP, DWG, and DXF.
•
Operates on Microsoft Windows platform.
•
Engineering e-mail address: bob@mamco.net
If developed in…
Transfer as..
Solidworks
Unagraphix
SDRC
Catia
Proengineer
.SLDPRT
Parasolid .XMT
.IGES flavored format for UNAGRAPHIX with trimmed surfaces.
.STEP
Parasolid .XMT
Through..
E-mail
MAMCO
Precision Moldings
20

R-S-009 Rev. C
Mold-A-Matic Corporation
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Offering full product and process development services.
In-house mold maintenance with prototyping capabilities.
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Utilize statistical process control (SPC) to maintain our operating systems and determine process capability.
Ensure quality is manufactured into all products; base all procedures on ISO and
QS 9000 requirements.
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Incorporating advanced quality tools such as Design and Process FMEA’s and
Mold Flow Simulation to ensure optimized mold and process development.
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Continue the pursuit of developing our employees through training and production teams. Ensure all employees understand the customers requirements.
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Develop specific production plans, customized to your quality, delivery and packaging needs.
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Assign each customer account to an account executive for personal and individualized attention.
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Utilize a strong and experienced group of technical engineers with expertise that includes designing, automation, quality systems and who grasp the emphasis on concurrent engineering and continuous quality improvements.
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Manage a worldwide staff of sales professionals who understand the intricacies of each market in which we operate.
MAMCO
Precision Moldings
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Mold-A-Matic Corporation
R-S-009 Rev. C
MAMCO’s desire to form a partnership with a customer can only be effective when both parties function as one and in the best interest of the other.
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MAMCO
Precision Moldings
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Mold-A-Matic Corporation
R-S-009 Rev. C
7.
Ejecting Part from Cavity
1. Type of Mold
3.
Gate and Runner Size and Design
(a) Material to be Molded
(b) Production
(c) Size of Part
(d) Dimensions
(e) Inserts in Part
(f) Shape of Part
(g) Machine Availability and Size
(a) Material to be Molded
(b) Dimensions of Part
(c) Shape of Part
4.
Gate Location
(a) Ejector Pin Location
(b) Possible Draft of Cavity
(c) Part Distortion
8.
Shrinkage of Material
2. Number of Cavities
(a) Production
(b) Size of Part
(c) Dimensions of Part
(d) Inserts in Part
(e) Machine availability and Size
(f) Cost of Parts
(a) Dimensions of Part
(b) Shape of Part
(c) Appearance
(d) Ease of Removal
5.
Ease of Cavity Correction for
Critical Part Dimensions
6.
Location of Split Line
(a) Appearance
(b) Ease of Cleaning
(c) Dimensions of Part
(d) Noted on Part Print
(a) Past Experience
(b)
Material Manufacturer’s
Literature
(Approx.)
(c) Size of Part
(d) Type of Mold
(e) Uniformity of Part
(f) Location of Gate or Sprue and Size of Gate
(g) Insert in Part
(h) Molding Techniques (Perform,
Cure, Pressure, etc.)
(i) Material Flow (Soft,
Hard, etc.)
(j) Design of Mold MAMCO
Precision Moldings
23

Mold-A-Matic Corporation
R-S-009 Rev. C
13.
Mold Base Selection
9. Type of Cavity Construction
11.
Side Draws
(a) Solid (Machined, Electrical
Discharge)
(b) Solid (Hobbed)
(c) Laminated
(d) Cast (Copper, Filled Epoxies, etc.)
(e) Plated Nickel and Copper
(f) Combination of Above
10.
Steel Selection, Heat Treat and Plating
(a) Production
(b) Material to be Molded
(c) Molding Pressures
(d) Design Cavity Details
(a) Loose Block
(b) Pull Pin
(c) Air Hydraulic
12.
Removable Solid Cavities
(a) Production
(b) Ease of Loading Inserts
(c) Cycle Time
(d) Multiple Inserts
(e) Repair of Cavities
(a) Type of Mold
(b) Type of Machine to be Used
(c) Molding Pressures Needed
(d) Cavity Layout
(e) Type of Mold Heat
14.
Type of Mold Heat (Oil,
Steam, Water, Electric, Platen or Cooling
(a) Temperature Required for
Molding Specified Material
(b) Size of Mold Base
(c) Type Available at Press
(d) Accuracy of the Heat Needed
MAMCO
Precision Moldings
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Mold-A-Matic Corporation
R-S-009 Rev. C
Injection Molding: Method of forming plastic to the desired shape by forcing the heat soft-end plastic into a relatively cool cavity (tool mold) under pressure
Thermoplastic Injection Molding: A process of thermoplastic polymers in which melted plastic is injected into a mold cavity, where it cools and takes the shape of the cavity, bosses, screw threads, ribs, and other details can be integrated, which allows the molding operation to be accomplished in one step. The finished part usually does not require additional work before assembling.
Insert: An integral part of a plastic molding consisting of metal or
Other material that may be molded into position during the molding
Process.
MAMCO
Precision Moldings
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Mold-A-Matic Corporation
R-S-009 Rev. C
Cycle Time
The total time required from shot to shot.
Draft
A taper on the side wall or core pin of a cavity to facilitate removal of the molded article from the cavity.
Ejector Pin
A pin used to remove the molded article from the cavity.
Pin
The part of the flash that is attached to the molded
Article.
Flash
The portion of the charge which flows from or is extruded from the cavity during molding.
Flow Mark
A visible mark resulting from the solidification of a pattern flow
Force
The part of the mold that transmits the pressure of the press to the top of the molding charge, for the material into the cavity.
Gate
A restriction in the runner at the point where the runner
Enters the cavity
MAMCO
Precision Moldings
26

Mold-A-Matic Corporation
R-S-009 Rev. C
Air Vent
A groove in a mold which allows the trapped gases in a cavity to escape.
Cavity
The portion of the tool that contains the opening for producing the desired shape and/or that area of the opening that forms the outer surface of the molded article.
Cold Slug Well
A space at the end of a runner or sprue to hold the cold slug and prevent it from entering the cavity.
Core Lines
The holes in the mold base and/or cavity through which passes a suitable liquid or steam to maintain the proper mold temperature.
Core Pin
A pin used to form a hold in the molded piece.
Cores
That portion of the mold that forms the required inner surface of the molded article.
Cull
The material remaining in the transfer pot after the mold is filled.
Cure of the Clamp Time
The time the mold is closed to allow the complete chemical change of the material of the material to take place and/or allow the material to harden enough for ejection.
MAMCO
Precision Moldings
27

Mold-A-Matic Corporation
R-S-009 Rev. C
Definition of Plastics (Society of Plastic Engineers): “Any one of a large varied group of materials
Consisting wholly or in part of combinations of carbon with oxygen, hydrogen, nitrogen, and other
Organic and inorganic elements which, while solid in the finished state, at some stage in its manufacture
Is made liquid, and thus capable of being formed into various shapes, most usually through the
Application, either singly or together, of heat and pressure.”
In more technical terms, plastics have the following:

Synthetic Material: That is, a material that is produced by man in the laboratory and not generally found in nature; Nature has provided the ingredients, but it took man to combine the certain natural elements in order to synthesize plastics.

Organic Compounds: Organic compounds are those that contain carbon; they are the compounds that have carbon to carbon linkage of atoms in there structure.

Processability: The plastic material must be able to flow at some stage before it becomes a finished product; the material must be capable of being formed, shaped or molded.

Polymerization: A plastic material is a polymerized substance. Polymerization is the combining of two high molecular weight organic compounds under heat or pressure or both, to form a larger molecule having different characteristics than the original molecules.
MAMCO
Precision Moldings
28

Mold-A-Matic Corporation
R-S-009 Rev. C
Specific Gravity: The ratio of the weight of a given volume of material to that of an equal volume of water.
Molding Shrinkage: Inches per inch; the differences per unit of a molded part, cold, and the cold mold.
Water Absorption: The quantity of water absorbed by a given test specimen for a predetermined period of time at a constant temperature expressed in percent gain.
Bulk Factor: The ratio of the volume of the nonperformed molding material to the volume of the molded part.
Plasticity or Flow: The capability of a molding compound to fill a mold under prescribed pressure and temperature.
Co-efficient of Linear Thermal Expansion: The ratio of the change in length of a specimen per degree C to its length at 0 degree C.
Impact Strength – Izod (Ft/lb. Per Inch of Notion): The energy required to break a standard notched specimen.
Heat Distortion Temperature (F) at Fibre Stress of 66 and 264 PSI: The temperature required to permit an arbitrary standard amount of deflection by a standard load.
Deformation Under Load (Cold Flow): Dimensional change under a constant load at a given temperature.
Tensile Strength – PSI: given test specimen.
The force required to break a
Heat Resistance F: The temperature to which a part, under load, can continually operate without change in physical dimensions.
Compression Strength – PSI: The measure of compressive load to cause failure.
Flexural Strength – PSI: The maximum fibre stress sustained by standard test specimen, calculated from the bending load required to break.
MAMCO
Precision Moldings
29

Mold-A-Matic Corporation
R-S-009 Rev. C
Modulus of Elasticity in Tension – PSI: The measurement of a force required to produce a given change in dimension.
Abrasion Resistance: The ability of a material to withstand mechanical action such as rubbing, scraping, or erosion. Expressed in volume lost.
Arc Resistance – Seconds: The measure of the time required to produce a conductive path between two electrodes to the total current between them.
Insulation Resistance – MegaOhms – Volume and
Surface Resistance: The ratio of the direct voltage applied to two electrodes to the total current between them
Rockwell Hardness: Resistance to penetration from a standard load applied to a spherical ball for a standard length of time.
Durometer Hardness –A, B, or D Scale: The degree to which a specimen can be indented under constant load by an indentor of fixed dimensions
Dielectric Constant: The ratio of the equivalent parallel capacitance, measured at a specified frequency of a capacitor in which the material is the dielectric to the capacitance of the same capacitor with a vacuum, or air, as the dielectric.
Dielectric Strength – VPM (Short Time Step-by-Step):
The average root-mean-square voltage gradient between two electrodes at which electrical breakdown occurs under prescribed conditions.
Light Transmission – Percent: The measurement of the percentage of luminosity transmitted through a solid material.
Flammability: The length of time, in seconds, a material will burn for a prescribed distance, after removal from the source of flame.
MAMCO
Precision Moldings
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