Gemini Group

United States

Vacuum FormingThe Vacuum Forming Process bonds sheet products such as vinyl and soft touch plastics to injection molded substrates for automotive interior trim products such as seatbacks and door bolsters. During the vacuum forming process, a heated sheet of plastic material is placed over a mold which is then moved towards the sheet and presses against it to create a seal. Next, the application of a vacuum draws out the air between the mold and the sheet so the plastic conforms to the mold exactly. The mold contains an integrated water cooling system which brings the temperature of the plastic to the required curing temperature. Once the curing temperature is reached and the piece is formed, air is blown back into the mold separating the new part from the mold. Advantages of Vacuum Forming Low Tooling Costs because of the low forming pressure used in the vacuum forming process, tools can be made from relatively inexpensive material

Twin Sheet Molding (also known as twin sheet forming) combines the process disciplines of compression molding, blow molding, and vacuum forming to mold, laminate, and trim multiple layers of materials (substrates with cover stock) in a one step process. The twin sheet molding process forms two sheets of plastic simultaneously through the use of a separate mold on the top platen and a separate mold on the bottom platen. Once the plastic sheets have been vacuum formed, they remain in their respective molds. While both sheets still remain at their forming temperature, the two molds are brought together under high pressures and the two sheets are bonded together. The result is a single product with hollow areas requiring no secondary bonding.

Water Shield & Water Deflector ThermoformingThermoformed water shields, also referred to as water deflectors, protect the vehicle interior by preventing debris, water, and noise from entering the vehicle in the door region.EVA, LDPE, TIASRobotically Applied AdhesivesAcoustic Management

Automotive Load FloorsWhile many automotive interior trim companies are compromising structural integrity and increasing product weight to meet cost targets, Valleys engineering team is uniquely equipped to help you optimize strength, weight, and appearance objectives of your load floor without sacrificing cost.Whether you need a Spare Tire Cover or a load floor that is 250 lb Knee Load Certified, Valley has the design, engineering and manufacturing expertise to assist with every aspect of you project.

BaypregValley Enterprises is one of the only manufacturers in the world with experience in developing and producing interior trim components containing Baypreg. Baypreg F is a two-component polyurethane system used in compression molding of natural fiber mats alone, or fiber-reinforced sandwich panels to produce a variety of composite automotive parts. The Baypreg F polyurethane system produces high strength, extremely lightweight and rigid molded composite parts.Baypreg has the highest strength-to-weight ratio of any material available in the marketplace today and is priced competitively with traditional materials.Very high flexural stiffness and excellent thermal properties; flexural strength 15-18 MPa @ 22C FeaturesExtreme rigidity at lowest mass per unit areaSolvent-freeExcellent wetting and adhesion with most common fibersFast processing through individual selection of temperaturesEasy processing (spraying, casting, knife application) in a two-component process using cost-effective machinery

Cargo Management SystemsUtilizing FEA and in-house rapid prototyping, Valley Enterprises predictably designs cargo management systems and launches new programs with exceptional control and speed to market.Design responsible2nd, 3rd Row Bin, Stowage, and Flipper PanelsIntegrated Components: hinges, handles, latches, hooks, cargo nets, dividersTufted or Non-woven Carpet

Rear Window Trim Rear Shelf Package TrayRear window trim components include rear shelves, package trays, integrated power sunshades, CHMSL, speaker grills, child theaters, and delicate Class A fabrics. The piece on the right incorporates all of these components creating a show piece for the all new Buick Lacrosse. Rear window trim assemblies are produced in Class A Surface finishes over various substrates in a one step process which molds, laminates and trims the part in a single step.

Automotive Door Trim BolstersSoft touch materials are wrapped over molded substrates giving automotive door trim and bolsters a Class A surface in addition to structural strength.Class A SurfaceVinyl, Fabric, or Carpet over material

Automotive Seatback AssembliesWhether you need a vinyl, vacuum wrapped, front row seatback or a carpeted, compression molded 2nd row seatback, you can lean on Valleys strong track record with both new domestic and domestic Tier 1s.1st, 2nd, 3rd Rows, Class A surfaceVinyl, Fabric, or Non-woven surfaceABS, PP, Hardboard, Natural Fiber