A plastic injection mold designer must consider many factors when designing injection molds, including the press the mold will run in. Knowing the press specifications is very important in order for the mold to operate properly, and most efficiently during injection molding production.
Vertical Press Clamping System The orientation of the clamping system is of course a very important consideration, as this determines whether the mold will open horizontally or vertically. A vertical molding press is used in over-molding production, also called insert molding because the molten plastic is molded around an object. An example would be an electrical wiring harness with plastic molded around a portion of it, clamps or even something like knives where the handle is molded around the metal. The insert in a vertical molding press can be either steel or even plastic. A vertical press requires molds for the top and bottom, as a vertical molding press has a rotary table which holds at least two bottom (B) sides of the mold, while the top half (A) half comes down to close on the bottom half molding the part. There is usually one top half, and at least two or more bottom sides to the mold, so that when the A side is molding the part on the back of the table, another B side is in front of an operator or a robot loading an insert into the open mold. Once molded, a robot or operator can unload the over-molded part from the mold, prior to loading new inserts into it. Constructing molds for a vertical molding press is quite different than for a horizontal molding press, even though the concept is the same. Horizontal Molding Press The most common type of injection molding operation is in a horizontal press, requiring an A side and B side, closing together on a horizontal plane to mold the parts. When the horizontal mold opens for ejection, parts usually fall into a bin below or are grabbed by a robot and taken to an inspection area. Most horizontal molding operations do not require an operator at the press, as the vertical over-molding jobs do without automated equipment. Horizontal molding presses are very efficient and non-labor intensive, with a top-quality high-performing injection mold, a horizontal molding operation can run for hours in a lights out environment. Regardless of whether the mold is for a vertical or horizontal press, the placement of water fittings and hoses is of the utmost importance in designing the tool. The clamping pressure and press tonnage are also very relevant specifications, in order for the mold designer to calculate the pressure of the molding operation while also considering the material chosen and how it will flow into critical areas. Michiana Global Mold has decades of experience designing tools for various plastic injection molding environments, meeting tight tolerances with high performing, precision custom injection molds. Download a FREE copy of our book “Design Considerations for Different Molds” for more information. Michiana Global Mold has decades of experience designing and building precision custom injection molds for various industries. Contact us today to speak with one of our knowledgeable engineers for a FREE design consultation on your mold building requirements. We can custom design molds for your applications, regardless of your molding environment.
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There are many advantages gained with using an ISO Registered mold making facility for construction of your injection molds. Plastic injection mold making shops are expected to meet just in time delivery deadlines with tight tolerances within specifications. Today’s injection mold making industry leaves no room for error as mold making shops must utilize modern technology with experience and in-depth knowledge of the injection mold making process in order to satisfy the stringent requirements of OEMs today.
The Internationally recognized quality standards of ISO9001, ISO/TS16949 and AS9100 set common parameters for various industries around the globe to measure their performance in either their service or product with a uniform set of standards. Any supplier to the Automotive industry should be registered to ISO standards. In some cases, proving compliance may be adequate for a 3rd tier supplier, although most 1st and 2nd tier suppliers must be registered to either ISO or ISO/TS. This gives Automotive suppliers around the globe the same set of standards to adhere to, making the job of the Automotive Quality Engineer from one of the top Automakers a little easier to compare vendors. In order to stay in the preferred vendor status, an injection molding shop and even the injection mold making shops must not only be registered to ISO standards, they had better be practicing their Quality Policy and performing continual improvement projects in order to stay competitive. Mold making facilities meticulously follow detailed checklists ensuring that all issues are recognized and address prior to cutting steel. ISO Registered mold making shops that follow Advanced Product Quality Planning (APQP) reveal any critical issues with mold construction such as critical fill areas to tight geometric areas, the need for CAM action, lifters or specialty ejection systems. Identifying these critical issues ahead of time is crucial to fulfilling a tight deadline with a quality mold. Michiana Global Mold is a global supplier of high quality injection molds, registered to ISO 9001:2015 and implementing our Quality Policy throughout the organization. We have been satisfying the stringent requirements of the Automotive industry with high-quality, custom, precision injection molds for over 52 years. Contact us today to see how we can assist you with your injection mold building needs. Copper and brass forgings provide high density parts with very accurate dimensions, achieving a high level of consistency. Brass forgings are used in several commercial and industrial applications such as automotive, aerospace, marine, transportation, plumbing, lawn and garden, heating and cooling and even the medical industry. Brass forgings are also used to provide durable strength in architectural applications. Due to the precision required of brass forgings used in critical applications, you need a brass forging die maker with expertise in tool making skills. Michiana Global Mold is a full-service tool and machine shop with vast expertise in manufacturing various molds and tooling, made with top quality components and precision accuracy. We have a large capacity modern tool making facility located in the heart of the Midwest in Mishawaka, IN, where we have been supplying quality molds and tooling for over 50 years! We specialize in complex, precision tooling and brass forging dies, manufactured to your specification within +/- .001”, and on time. Michiana Global tackles the complex designs and intricate tooling that others shy away from. With confidence and experience, we can manufacture your brass forging dies within your tight tolerances, and deliver high volume projects on time. We manufacture forging dies with a heat treated and polished finish, for single or mass produced production requirements. With a full-service tool shop, we also do engineering changes if necessary, saving you time and money. We utilize a full line of CNC machines manufacturing brass forging dies with cost effective, efficient solutions, giving you the best value. Our expert design an engineering team can provide a free design consultation or provide reverse engineering services with our experience and CAD/CAM software and equipment. We adhere all processes to our strict quality policy as an ISO registered mold and machine shop. Established since 1964, Michiana Global Mold has over 50 years of experience providing custom, precision injection molds, tooling and forging dies. Contact us today for a free design consultation and to see how we can save you money on your procurement of brass forging dies. Most injection molders and injection mold makers are well familiar with the standard mold base, consisting of two halves, referred to as the A and B side of an injection mold. The standard mold base will have two sides, and gates where the plastic will flow into the mold, through a ‘channel’ to get to the cavity or multiple cavities where the parts will mold. This standard mold base is also called a cold runner mold. When the polymer resin hardens in the cavity to form the part, it hardens in the channel as well, which is also called the runner or the sprue. In most cases, the runner is scrap, and will either be ground up and kept in raw material inventory as regrind to possibly be used in future jobs that will allow it, or it will simply be thrown away. Some injection molders grind up runners and keep the regrind material, but it can pile up and become an eyesore as most injection molding jobs require the use of 100% virgin material. Even if it can be reused, it’s value is greatly diminished if it is stored in inventory. Some molders feel it’s not worth the space on the floor to keep regrind material. If this runner is large, it can be a huge expense built into the part production, as the cost of the material is one of the biggest, if not the biggest expense of producing the part. In some cases, especially for extremely small parts, the runner is larger than the part being produced. In cases such as this it may be advisable to construct a hot runner mold. A hot runner mold has a nozzle at each cavity supplying plastic directly into the cavity, rather than flowing through a ‘channel’, creating a runner. This is a big saver if you can avoid creating a large runner for a high-volume production job. Hot to Cold Injection Mold A hot runner mold may be worth the investment in cases of excess waste with high volume, although it is typically quite a bit more expensive than a cold runner mold. Another option is called a hot-to-cold mold which is a hybrid of the two. Rather than have a nozzle at each cavity, there is a nozzle supplying a shortened runner system, supplying material to more than one cavity, thus greatly reducing your material cost. A benefit of a hot-to-cold mold as opposed to a hot runner mold is the cost, it is generally less expensive as there are not as many nozzles and inner workings. A hot-to-cold mold is often the most economical option, providing significant cost savings with a reduced runner size, while not imposing the added cost burden of a full hot runner mold. Michiana Global Mold is experienced at constructing cold runner, hot runner, and hot-to-cold runner molds. We have been in business for over 50 years, providing high performance tools with complex, precision designs. Contact us today for a FREE design consultation and to learn more about how Michiana Global Mold can reduce your purchased injection mold costs. Injection molding is the mass producing of plastic parts with a steel mold, an injection mold, designed with cavities to mold the desired part. Injection molding uses thermoplastic resins, also called polymers, typically in a raw pellet form, that melt and flow into the cavities in the mold, forming the part, then it is ejected once it hardens. The time that it takes for the mold to close, plastic to flow into the mold, the polymer to set and eject upon mold opening is called the cycle time. Injection molders are always looking for ways to increase the cycle time, as time is money and when you can mold a part faster, you can mold more per hour, per day and per week.
A skilled injections mold maker will have the knowledge to design the mold with the most appropriate attributes to reap the best cycle time while still delivering the desired part to the customer specification. Michiana Global Mold is accustomed to constructing complex, precision injection molds within +/- .001”, which is about the thickness of a human hair. Injection Mold Making Equipment Injection mold makers are well familiar with the precision equipment used to carve out steel cavities, forming a perfect plastic part. Computer aided design, and computer aided manufacturing (CAD/CAM) equipment is a key tool for designing a perfect tool. The designers at Michiana Global Mold use Unigraphics CAD/CAM software to design the mold fit for producing a desired part. This alerts the mold maker and the injection molder to any critical areas such as thin walls or a critical dimensional tolerance that must be met, prior to cutting steel. Milling machines, conventional EDM and wire EDM machines are a necessary tool, along with high speed CNC machines, drill presses and grinders. Michiana Global mold, located in Mishawaka, Indiana with an offshore mold making facility in China, utilizes all of these mold making equipment tools, and more. We have over 50 years of experience constructing complex tooling for demanding industries such as the Automotive industry where 0 ppm (parts per million) defects is the norm. The key to a quality plastic injection molded part, is a quality injection mold. No one understands this better than Michiana Global Mold, your one stop shop for mold making and tooling services. We do everything from constructing insert cavities and prototypes to full service high volume precision production tools. Michiana Global Mold is Registered to ISO9001:2015, delivering custom injection molds to a wide array of industries demanding high volume long lasting performance with the best available pricing. We offer rebates on multi-tool programs and discounts with offshore molding options. Contact us today for a FREE design consultation, and to see how Michiana Global will provide value added services in your supply chain. Injection mold making is a very critical, precision process that requires not only knowledge and resources, but also experience. Experienced journeyman mold makers make all the difference in the world when it comes to creating a quality crafted injection mold versus a sloppy tool that barely makes the mark. Having experience with building precision tools for a multitude of applications gives invaluable skill that cannot be learned anywhere else. An experienced journeyman mold maker is a valuable component of the injection mold making process. Experienced Journeyman Mold Makers at Michiana Global Mold At Michiana Global Mold we employ a highly skilled design and engineering staff and master journeyman mold makers with in-depth knowledge and vast experience in designing and constructing precision, complex tooling. We partner with you from the very beginning, coordinating on every aspect of your project with clear, transparent communication. Our experienced team draws on traditional methods, combined with our cutting-edge technology, to provide the best solution for your precision injection mold requirements. Our large capacity facility in Indiana is equipped with conventional EDMs and wire EDMs, CAD/CAM engineering equipment, CNC milling centers, grinders, drills and saws. One of our knowledgeable staff can assist you in determining the best type of tool for your project, with the most cost-efficient method while not compromising precision quality. Michiana Global Mold specializes in manufacturing tight tolerance, complex, precision tooling. We have the experience and the resources to provide the perfect tool for your project, on time and within specification. Michiana Global Mold provides custom injection mold making for any required tooling operation. We are experienced at manufacturing hot and cold runner molds, hot to cold molds, insert molds, shuttle molds and prototypes. Our production molds are built with experienced craftsmanship, and only the best in quality components. Michiana Global Mold has been in business since 1964, serving the injection mold making industry for over 50 years! We are an ISO9001:2015 Registered mold making facility with domestic and off-shore molding capacity. We have the experience and the resources to provide quality molds for any molding application, and the resources to handle multi-tool packages within specification, and on time. Avoid Costly Runners A hot runner mold is desirable in situations where you would have a large runner that would go to waste, thus raising the cost with excess material. While the cost of a hot runner tool may be more than a standard cold runner mold, an economic analysis may reveal that the cost savings could pay for itself in a reasonable amount of time. This would be especially true if the material is a costly specialty raw resin. Improve Geometrical Tolerances In a hot runner mold, the material is injected directly into the cavity through a nozzle, rather than flow through the runner system. This is done with more pressure than a cold runner tool, and can improve filling and packing into critical dimensional areas. The pressure utilized in a hot runner tool can improve consistency in the molding process, thus improving the quality of the parts. Improve Cycle Time Due to the increased pressure, a hot runner tool may bring an improvement in cycle times. All plastic processors know the value of an improved cycle time as increased efficiency equates to increased profits. When applied to a multi-cavity tool on a high-volume project, the savings in cycle time alone could be quite significant, not to mention improving lead times with production parts. The volume of production required from the tool is a big consideration when weighing the benefits of a hot runner tool versus a cold runner tool. Flexible Gate Location A hot runner tool allows for flexibility with the gate location, which can be placed in the most desirable area for consistent filling and packing. In parts with high visibility, gate location is important to the aesthetics as well as function of the molded product. There are two different types of gating mechanisms for hot runner tools, a thermal gate or hot-tip gating system, or a valve gate. With a thermal gate the nozzle hardens at the tip, allowing the parts to disconnect from the nozzle prior to ejecting. In a valve gating system, a valve slides over the nozzle tip prior to ejecting, assisting with ejection if the material does not solidify completely in the tip. Michiana Global Mold has knowledge and experience designing and manufacturing precision hot runner tools for customers demanding a high level of quality. Contact Michiana Global Mold today for a free cost analysis of your next mold building project. A Shuttle mold is a mold system with one A side, and multiple B sides. This is used in a vertical clamping press, as opposed to a horizontal clamping press. A vertical clamping press is used for over molding, also referred to as insert molding. Insert molding occurs when plastic is molded around an object such as a metal or even another plastic insert. A shuttle mold system is used on a rotary table press so that there are two, three or sometimes four bottom sides, rotating around on the table allowing an operator or a robot to place the insert into the cavity in the mold. When the bottom side spins around, the top half of the mold will come down vertically clamping onto the B side to mold plastic around the insert. This system can be labor intensive requiring an operator to load inserts, and unload molded product, unless the job is set up with automatic robots for this purpose. This is different than most horizontal molding processes in which the there is one A and B side of the mold, sliding on a horizontal plane, coming together for the injection molding process, then the parts are automatically ejected with an ejector system falling into a desired location, usually a bin or box underneath the mold. Most horizontal injection molding jobs are fully automatic once the mold is set in the press, some can even run in a lights-out situation if automated auxiliary equipment is established. A vertical molding press with a shuttle mold system typically employs an operator, although they can also be automated. Some examples of insert molding would be electrical wire harnesses that are partially encased in plastic, or even knives or silverware that have plastic molded around a metal object. Shuttle molds are used in plastic injection molding for various industries including Electronics, Consumer Goods, Automotive, Aerospace and Military / Defense industries. Michiana Global Mold has experience constructing precision shuttle molds, and virtually any other type of plastic injection mold base used in various industries. We are a valuable supplier to the Automotive industry with complex tools meeting tight geometrical dimensional specifications. Contact Michiana Global Mold today, and ISO9001:2015 Registered mold maker. When constructing plastic or rubber injection molds, in addition to the part design the molding environment that the tool will run in is of the utmost importance. A mold designer must be aware of the injection molding process that the tool is designed for, the press it will run in including the clamping system and whether or not it is a vertical or horizontal clamping press. Each injection molding press will have a particular clamping pressure that is either delivered in an electric or hydraulic system. Some molders prefer to use all hydraulic presses, while some have a mix of hydraulic and electric, while other molders use only electric machines. There are some benefits to both, but the mold designer must be well aware of the power and pressure utilized in the press of choice prior to designing and constructing the injection molds. A mold designer, and mold builder will need to know the tonnage of the press, the clamping orientation and clamping pressure whether it is electric or hydraulic, and they will also need to know the barrel capacity of the press. This will determine how much material will be able to flow into the mold, and based on cycle times and cavitation, will determine whether or not the tool is designed to meet projected production volume requirements. Each injection molding press will also have a certain type of mounting system to secure the mold in the press. A toe-clamping system is most common, although a skilled mold designer can adapt the tool to fit even a custom designed mounting system. The platen must be large enough to hold the mold but it must also allow enough room to pass through the tie-bars when loading or unloading the mold. The tie bars hold the mounting platens in place which securely hold the mold in the press, and also contain the ejection system allowing opening and closing of the mold. Michiana Global Mold has vast experience designing complex, precision molds for various industries, meeting all requirements of our customers molding environment. We are valuable addition to any supply chain, providing proven solutions with high performing quality steel molds. Contact us today for a free design consultation, and to learn more about our discount and rebate programs. Are you looking for an injection mold supplier that can provide globally sourced injection molds, at a competitive price, and still provide domestic support? Look no further! Michiana Global Mold is located in the heart of the Midwest, employing skilled journeyman moldmakers and technical design engineers providing quality precision tools since 1952. We also have a facility in China, Modular Mold, offering full service injection mold design and construction. Modular Mold in China is ISO Registered, as well as our domestic location in Indiana. With Modular Mold in our China location, we have the ability to provide you with fully finished or semi-finished molds, with the same technical expertise, attention to detail and precision that you will find from our location in the United States. When you need overseas pricing on injection molds, with domestic service and support, you need a supplier like Michiana Global Mold. We manage your project from our Indiana location, providing you with one main point of contact to assist you the entire way throughout the scope of your project. All tools are inspected and tested for 100% accurate precision dimensions and conformance to your requirements, prior to shipment. Modular Mold is over 40,000 square feet, with capabilities to produce molds to accommodate presses up to 3,000 tons. By following our quality policy and adhering to all requirements of ISO9001:2008, we focus on quality, precision, and lead times. If you need a quality constructed tool with tight geometric tolerances used for precision injection molding applications, you need to call on Michiana Global Mold! We are your one stop shop for quality injection molds whether you need domestic or overseas suppliers, we provide top notch customer support. You will never experience problems due to a language barrier as we handle all communication and make regular visits to our China location. Let us show you how you can save up to 40% on your injection molded products by using our experience and resources for your next injection mold construction needs. For more information on our China location, see our recent blog “Domestic Service with Benefits of Mold Makers in China”. Michiana Global Mold is a supplier of superior quality plastic injection molds for various industries including automotive, medical, consumer electronics, and defense for over 50 years. We maintain high customer satisfaction through continual product and process improvement at both our United States and China locations. |
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