Plastic Mold Making

Plastic Mold Making

To achieve the desired mold productivity, many elements of plastic mold making and design must be intelligently incorporated. The basics of design for plastic mold making must be the starting point and then added to that, decisions made about a whole host of different design options must be made to work in concert with the basics to come up with an optimized mold design.Plastic Mold

Everyone is interested in having the lowest cost tool, but in plastic mold making, other considerations must also be included. Among these is the mould’s ability to be readily maintained, and kept in optimum condition throughout the mould’s useful life. A very low initial cost tool may prove to have a larger overall cost of operation; if for instance, lengthy maintenance procedures are required to keep the tool in operational condition throughout its life.

There are two general types of cavity and core inserts that should be considered when plastic mould making: Integrated and Nested or Split Structure. Each has its advantages and disadvantages, so the decision about which to choose when plastic mold making depends on the application and the required useful life of the mold.

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Integrated Cavity

The integrated cavity is cut directly into the mold base plates. It requires the fewest number of parts and is the simplest to produce, so often (though not always) this is the least expensive to produce in terms of initial investment. However, as stated, this is not always the least expensive alternative when considering the cost of the tool over the life of the part.

Some of the Advantages of Integrated Cavity Mold Making include:

• More practical for large or odd-shaped parts, such as automotive body panels and similarly shaped parts.

• Least amount of machining – so lower initial cost.

• Least amount of mold materials used – so lower materials cost.

Conversely, some of the Disadvantages of Integrated Cavity Mold Making include:

• Requires larger, more expensive machines to make the molds, and no components may be made in parallel, so they often have a longer lead time to produce.

• Most costly, difficult and longer lead time to modify in the event revisions are required.

• Costly and difficult to repair with longer down times when the mold wears or is damaged during its useful life.

Nested Cavity

When making a nested cavity plastic mold, cutouts are made in the mold base to receive nested parts that form the mold cavities that produce the finished parts. While this has more components than the Integrated Cavity type, often the advantages of plastic mold making using this method far outweigh the disadvantages.Plastic molds

Advantages to using Nested Cavity plastic molds making:

Complex geometries may be more easily formed when using nested cavities, for example, multi-pin electrical connectors are nearly always made with nested cavity tools.

Improved materials may be more easily incorporated into nested cavity molds for reduced wear and improved mold temperature control ability.

Damaged or worn components can be quickly and inexpensively replaced to minimize downtime.

Some of the disadvantages of using Nested Cavity plastic mold making include:

• Higher initial material costs

• More machining required in some cases, as both the mold base and the cavities require precision manufacture. (However, most of the machining may be performed on smaller, faster and less expensive machines.)

Consult with your mold maker to decide which of these two different plastic mold making philosophies are most suitable for your specific application. if you want to know more about us please got to our home page to know more about us

Precision Injection Mold Making

Precision Measurement And Injection Mold Making

It is remarkable that it is possible to open a package from Sweden, clean up EDM tool, and install it in an engine lathe spindle made in upstate New York, and indicate the run-out with a dial indicator made in Switzerland, held by a magnetic base made in Japan. This is amazing in itself, but the truly amazing thing is that it all works, quite well!

In this example, which actually happened to me, the run-out was less than .0001in/.0025 mm, right out of the box, first try. This is what precision tool measurement is all about.

The number of precision tools used by an injection mold maker are numerous. A partial list would include:

Precision measurement tools

  • Granite surface plate
  • Surface gage
  • Dial indicator
  • Height master/Cadillac gage
  • Gage blocks
  • Pin gages
  • Sine plate
  • Magnetic squaring block
  • Vee-block
  • Precision micrometers
  • Spin fixture

One of the more challenging aspects of building a mold is to have all of the various measuring tools calibrated to the same standard. This is why the EDM chuck from Sweden fit in the American lathe spindle: the accuracy was traceable to a common standard.

It doesn’t mean much if you are accurate within .0002 in., if your micrometer is off! It just won’t work. Shops need to have a master set of gage blocks that are traceable to the NIST, or National Institute of Standards and Technology. This is not as hard as it sounds, you just need to invest in a good set of gage blocks, not some made by child labor in a developing nation.

The proper care and use of these expensive tools is critical as well. They need to be treated with respect, handled carefully, kept free from rust and grinding grit. They need to have a clean storage place, with a grit-free surface on which to sit.

There are many places that you can cut costs in Plastic mold making, precision measurement tools is not one of them. It simply makes no sense to save money by buying a cheap dial indicator, for example. It is only going to haunt you in the long run. The same holds true for gage blocks, micrometers, squaring blocks, sine plates and so on.

With large items, such as the optical comparator or coordinate measuring machine, it is especially important to obtain a reliable tool. Valuable shop time can be quickly consumed with trouble-shooting a low quality machine. Not only that, but what if the measurements are unreliable? The mistakes can become extremely expensive and will quickly erase the initial savings.

Reliable precision measurement manufacturers

 Starrett Brown-and Sharpe Interapid Girod
 Etalon Mitutoyo Suburban Mahr
 Tesa Hermann Schmidt OGP Magnets
 Harig Micro-Vu Mitutoyo Zeiss

Insert Molding

Insert Molding Advantages

Over the years, the technical advancements have taken place and instead of step-by-step manufacturing of products, there is manufacturing through one full-fledged process called insert molding . Certain industries still manufacture components through processes that include assembling discrete parts such as soldering, connectors, adhesives or fasteners. Molding through inserts is the perfect alternative to all such things and can benefit you in the following ways:

Decreased labour cost and assembly

Simply because various components are being joined or connected through thermoplastics, you can greatly bring down the assembly as well as labour cost with the help of this process.

Decreased weight and size

This process can yield smaller as well as lighter components by eliminating the need for connectors or fasteners. It merely blends the strength of metal inserts and resin.

Increased reliability

This process helps you in avoiding problems such as misalignment, part loosening, and improper termination as well as other problems. Every single part is secured tightly with the thermoplastic.

Design flexibility

Plastic Molding

Insert Plastic Molding

Another advantage of the insert molding process is that it gives you design flexibility. Designers love the unlimited configurations which can be used in insert plastic molding.

This process can literally allow you to reduce cost and experiment with the designs apart from getting other advantages as well. Most of all, it can allow you to save time and faults that might occur in manufacturing components otherwise. In a lot of ways, this process can be used by various industries to produce high quality and efficient components for all the purposes.