HEAT SHRINK NOZZLES FROM MALCOM

HEAT SHRINK NOZZLES

Customer

U.S. DOD

Partner(s)

Leister

Applications

Adhesive Removal, De-icing, Heat Treatment, Overlap Welding, Pre-heating or Warming, Shrink Labels, Shrink Tubing, Soldering

Industries

Aerospace, Airline, Aviation, Construction, Electronics, Fire Prevention (Heat Sensors), Flooring, Forensics, Oil Platforms & Refineries, Power Plants, Roofing, Ship Building, Signs & Banners, Transportation & Shipping, Warehousing & Logistics, Waste Management (Landfills), Waterproofing

Malcom Company offers a wide range of heat shrink nozzles for many types of heat shrining applications.  Malcom can custom make nozzles to suit our clients needs.  Contact us today to discuss your heat shrink applications with our application engineers.

 


MCH-100-HM HOT MELT TOOL

Customer

U.S. Government Contractors

Partner(s)

J & J technologies, ESICO, Antech

Applications

Curing Composites, Hot Melt Smoothing

Industries

Aerospace, Airline, Aviation

CHALLENGE:

To design a tool for use on composite outer skin on aircraft for smoothing hot melt plugs into voids on the surface;  powered by the same 48 VDC power supply used by the MCH-100-A heat gun power supply and have adjustable temperatures with a digital readout of the set and actual temperatures. 

SOLUTION:

We began the process by contacting our suppliers about the project to see if they would be able to provide the needed COTS components, including the heating element, thermocouple and control system to build the tool with.  The response was positive and we proceeded purchasing the needed components and within a few weeks assembled the first tool and called it the MCH-100-HM tool, HM for Hot Melt.  After tests were completed we presented the prototype to our customer who was receptive and interested in what we had to offer and so we pursued further development and refinement.

Within months our customer released a solicitation (RFQ) for the tool which we responded to. The RFQ was in the form of source control drawings which detailing the customers specifications and requirements of the tool. The drawings called for very precise temperature controls (+- 15 degrees at the tip) including a digital readout of the set and actual temperatures. Before we responded to the solicitation we sourced additional COTS temperature and power controllers that would work on 48 VDC power.  We assembled a second prototype and conducted additional tests which proved successful. We then proceeded to partner with a machine shop to machine the hardware components needed to meet the requirements and finished the prototype.

The MCH-100-HM tool was made with nearly all COTS components, with the exception of the machined parts associated with the handle and control box, that were then assembled into the finished tool and tested.  With positive test results in hand we felt confident that we could deliver what our customer was looking for and responded to the solicitation and were eventually awarded the contract.

In the end what we had accomplished was using tools and components that were already available in the commercial marketplace and configured them in a way that met the requirements of our customer.  This resulted in very low development costs and delivery of the product to our customer in less than one year.

The solicitation required that the tool pass all the same military standards of the MCH-100-A tool including explosive atmosphere, drop test, rain intrusion, EMI, salt fog and more. The tool was designed to these requirements and passed all of the tests performed.

What we ended up developing is the Malcom portable battery powered Hot Melt Tool that is not only used commercially for the original customer for hot melt plugs but can be used in other applications such as soldering and shrinking applications in the commercial marketplace that require precise temperature control.




BATTERY POWERED HEAT GUN

MCH-100-A HEAT GUN

Customer

US Navy

Partner(s)

Leister, Bren-Tronics, Fieldtex, J & J technologies, Skydyne, Aircraft Dynamics

Applications

Adhesive Removal, De-icing,  Heat Sensor Testing, Heat Treatment, Overlap Welding, Plastic Welding, Pre-heating or Warming, Shrink Labels, Shrink Tubing, Soldering

Industries

Aerospace, Airline, Aviation, Electronics, Fire Prevention (Heat Sensors), Oil Platforms & Refineries, Power Plants

Malcom Manufactures a line of powerful battery powered tools.    The MCH-100-A is the post powerful battery powered heat gun on the market today.   Malcom's other battery powered tools include the following:

 

 

 


MCH-100-C BATTERY POWERED HEAT GUN

Customer

Fire Alarm Service & Testing

Partner(s)

Leister, Aircraft Dynamics

Applications

Heat Sensor Testing, Shrink Tubing, Soldering

Industries

Aerospace, Aviation, Electronics, Fire Prevention (Heat Sensors), Oil Platforms & Refineries, Power Plants

CHALLENGE:

To design a power supply and charging system that is less expensive and geared towards the general industry customer.

SOLUTION

The MCH-100-C Battery Powered Heat Gun includes the 111.038.2 Heat Gun, a powerful 42 VDC Battery Powered Heat Gun with a standard 300W element that produces temperature capabilities ranging from 500F to 950F dependent on nozzle choices and available as additional accessories.  The Heat Gun produces an airflow of 2.66 CFM at an air pressure of 16-mbar and weighs less than 2 lbs with a 9 foot power cord. Temperature ramp-up from ambient conditions is 60-90 seconds with a continuous run time of 25-30 minutes.

The Heat Gun is powered by the rechargeable A-3916 Robopak 48VDC Sealed Lead Acid Glass Matt Battery with LED Battery Level and gas gauge capable of redeployment within 6 hours of charging using the kit included Robocharge Battery Charger. The rugged battery case includes a carry strap and weighs 26 lbs. The state-of-the-art high performance battery charger utilizes a 4-step microprocessor technology charging system.

DEVELOPMENT

Adapted from the MCH-100-A Military Standard Battery Powered Heat Gun Kit, the MCH-100-C was developed to offer a low cost Battery Powered Heat Gun option for testing heat sensors, shrinking and soldering electronics, plastic welding, repairing tents, tarps, and boats, and providing mobile heat for a myriad of applications that does not sacrifice the proven and reliable functionality of the original MCH-100-A system.

Currently, Malcom has delivered nearly 3,000 MCH-100-A and MCH-100-AB Battery Powered Heat Gun Kits to all branches of the Department of Defense, including the Navy and Marines, Air Force, Army and National Guard, as well as NASA and Homeland Security, and industrial customers in the Aerospace, Energy, Manufacturing, Research and Maintenance sectors. Innovation continues as new applications demand and has resulted in developing accessories such as the MCH-116 Soldering Iron, the MCH-100-HMD Hot Melt Iron, and MCH-100-HB Hot Bonder.




BATTERY POWERED SOLDERING IRON

MCH-116 KIT - DC SOLDERING IRON

Customer

U.S. DOD

Partner(s)

J & J technologies, ESICO

Applications

Soldering and De-Soldering

Industries

Aerospace, Aviation, Electronics, Hobby

CHALLENGE

To produce a soldering iron powered by the same power pack as the MCH-100-A uses.

SOLUTION

Soldering Iron Kit with different soldering tips that is all able to run off 48V DC power.

 

 

 

 

 


MCH-100-AB Battle Damage Assessment and Repair Heat Gun and Soldering Iron Kit

MCH-100-AB - BDAR KIT

Customer

US Army

Partner(s)

Leister, Bren-Tronics, Fieldtex, J & J technologies, ESICO, Skydyne

Applications

Shrink Tubing, Soldering

Industries

Aerospace, Aviation, Electronics

CHALLENGE:

To design a kit that includes the items specified by the US Army for part of their battle damage and assessment kit.

SOLUTION

The MCH-100-AB Battle Damage Assessment and Repair Kit includes the standard MCH-100-A Battery Powered Heat Gun Kit and MCH-116 Battery Powered Soldering Iron with an additional 20 mm Spoon Reflector Nozzle and robust Pelican transportation case.

DEVELOPMENT

The US Army Battle Damage Assessment and Repair Team at Redstone Arsenal required a portable electric repair kit to rapidly return disabled equipment by applying field-expedient repairs to damaged electronics, components, wiring, and cables in the field.

In general, BDAR restores the minimum essential combat capabilities necessary to support a specific combat mission or to enable the equipment to self-recover. BDAR is accomplished by a creative "work with what you have" approach and typically involves bypassing components or safety devices, the cannibalizing or controlled exchange of parts from like or lower priority equipment, fabricating repair parts, jury-rigging systems, taking shortcuts to standard maintenance, and using substitute fluids, materials or components.

Battle Damage Electrical Repairs require the ability to solder and desolder as well as apply heat shrink to insulate installed electronics in harsh field conditions. Malcom responded with a combination repair kit that included the MCH-100-A, developed as a portable, handheld, robust, powerful, and adaptable convective heat tool to repair avionics in harsh wind, rain, salt-fog, desert, arctic, explosive atmosphere, and electromagnetically sensitive environments, and the MCH-116 Battery Powered Soldering Iron developed as a heavy-duty accessory to the MCH-100-A.

TESTING

MIL-STD testing conducted:

  • MIL-STD-461E EMI Control, RE101
  • MIL-STD-810F Environmental Tests
    • 511.4 Explosive Atmosphere
    • 506.4 Rain Intrusion
    • 509.4 Salt Fog
    • 516.5 Shock

DELIVERY

Currently, Malcom has delivered nearly 3,000 MCH-100-A and MCH-100-AB Battery Powered Heat Gun Kits to all branches of the Department of Defense, including the Navy and Marines, Air Force, Army and National Guard, as well as NASA and Homeland Security, and industrial customers in the Aerospace, Energy, Manufacturing, Research and Maintenance sectors. Innovation continues as new applications demand and has resulted in developing the MCH-100-C, a low cost Battery Powered Heat Gun, and accessories.