Injection mold designs today must meet tough customer specifications, calling for critical fill areas with precision mold designs. Careful planning must be taken when designing complex molds for critical applications, ensuring consistent packing and filling to tight geometric tolerances. A qualified mold design engineer has several important considerations when beginning a complex injection mold construction, beginning with a carefully planned mold design.
CAD/CAM for Mold Design Computer aided design and manufacturing is a valuable tool for injection mold designers, providing accurate 2D drawings and designs to meet customer specifications. The use of CAD/CAM is beneficial when constructing molds for any industry, especially when designing and constructing injection molds for the automotive industry. Unigraphics and SolidWorks are two of the most technologically advanced software design programs used to satisfy the complex demands of the automotive industry. Mold Flow Analysis is another valuable tool to identify potentially challenging fill areas, especially when using a specialty resin that may be unfamiliar to the molder. These computer simulations are part of a thorough Advanced Product Quality Planning (APQP) set of procedures which ensure a successful mold launch. APQP procedures are critical to the planning phase as following a detailed set of procedures identifies any issues with resin, geometric challenges such as a thin wall or critical dimensions that must remain within +/-.001” for proper functionality. Michiana Global Mold utilizes CAD/CAM software as part of our thorough APQP procedures, to ensure a quality constructed mold for even the most complex of mold designs. As an ISO registered injection mold making shop, we are experienced with providing a quality mold made to customer specifications, on time and within budget. We work closely with our customers to develop a successful mold launch to meet even the strictest of specifications. Contact us today to speak with a knowledgeable design engineer, and Download our FREE Book on Design Considerations for Different Molds. Michiana Global Mold is an injection mold design and mold making company, constructing precision molds to various industries since 1964. We are an ISO registered injection mold making facility satisfying the strict requirements of the Automotive industry with high quality precision molds. Contact us today for a FREE design consultation.
0 Comments
Injection mold design includes design of the optimum ejection system to meet part specification. While ejector pins are most commonly used, there are other methods of ejection systems that are required in specific situations.
Ejector pins are round, and used to extend into the cavity to push the part out during mold opening so that the parts fall out or are pulled out by a robot. Pins are adequate in most situations, although some part designs require pins along with an alternative method, or a different method altogether. Ejector blades can also be used for ejection if the part design requires it, and these have more of a rectangular geometry. Ejector blades are often used in designs where a thin wall exists, thus an ejector pin may damage the part with force or pressure applied in a critical area. Ejection sleeves are tubular, and are ideal in areas of raised surfaces. These raised surfaces are designed to assist with assembly in some designs, for example a raised hole at the end of a vertical part would be referred to as a boss. Ejection sleeves provide 360° surface around the boss for easy part ejection with these types of part designs. A stripper plate is another type of ejection system that consists of an entirely separate moving plate, that is designed to strip the part or parts from the core of the mold. These are ideal in situations where you need to keep parts and runners separate, and are utilized in three-plate tool. Michiana Global Mold is a leading global injection mold design and construction company, with extensive experience in all types of ejection systems. Our skilled mold designers and journeyman mold makers have extensive knowledge and experience with various types of mold construction. We construct prototype molds with sample parts, cold runner or hot runner tools, shuttle molds, insert cavities and all aspects of injection mold design including engineering changes. Michiana Global Mold was established in Indiana in 1964, serving various industries and specializing in complex, precision tools for the Automotive industry. We offer a partner company in China with offshore mold making capabilities. Both facilities are registered to ISO 9001 and follow strict quality management systems. Contact us today for a FREE design consultation and to speak with a skilled design engineer. Injection mold designers must always take into consideration the surface finish required of the finished molded part. The ejection system in the mold that removes the solidified parts out of the mold cavity or cavities has great impact on the part’s surface finish. The most common ejection system uses ejector pins which can leave marks on the part, often referred to as witness lines.
An experienced mold designer will position ejector pins in order to place witness lines in an area acceptable to the part print. The ejection system and ejector pins are housed in the B side of the mold, extending into the cavity during ejection then retracting back into the mold. Restrictions on ejection must be apparent prior to mold design, if ejector pins cannot be used without damaging the part, lifters can be utilized for proper ejection. The injection mold design must correspond to the ejection pattern and stroke of the press. Michiana Global Mold is an experienced injection mold maker with in-depth knowledge of designing various ejection systems to meet customer specifications. We use CAD/CAM Unigraphics software to design and develop a layout for the ejection system prior to cutting steel. In some cases, ejection systems must be designed around robotic arms that reach into grab the parts upon ejection. These robotic systems are called ‘sprue pickers’, as sprue is another term for the runner that is also ejected with the part. Some ejection systems automatically separate parts and runners, so that they do not need to be separated later. Whatever your part design, surface finish, or ejection system is required, Michiana Global Mold will design and construct a superior mold with flawless ejection for the specified part surface finish. We are an ISO registered mold making company with an offshore mold making partner in China. Contact us today for a FREE design consultation and to speak with a skilled mold engineer. Injection molding companies that manufacture precision parts are often in need of a precision injection mold making company to add to their preferred vendor list. Many quality and purchasing engineers in various industries are searching for a custom mold making company with high precision capabilities to manufacture critical components.
Some industries that require vendors with precision capabilities to produce to high performing parts and components are:
In addition to the molding parameters such as the size of press, and the material used, the mold design has vital impact on the quality of the parts produced in the manufacturing process. Mold Design for Precision Parts Manufacturing Producing precision parts consistently to customer specifications requires a flawless mold. The mold design will be based on the part design, usually provided by the customer. In some cases, an experienced mold designer can assist with reverse engineering for new product design. Experienced mold design engineers will use computer aided design (CAD) software to assist with an injection mold design, providing detailed prints that can be shared with the injection molder for collaboration on critical areas. When necessary, mold flow analysis can show the mold maker, and the injection molder a detailed computer simulation of how the material will melt, flow and fill. Precision parts molders need a precision mold maker in their vendor list, a mold maker like Michiana Global Mold that offer value added services with custom injection molds within specification, and delivered on time. For full service mold making and tooling services from an experienced, professional and high performing mold making company, contact Michiana Global Mold. Michiana Global Mold is a leading mold making company supplying injection molds to OEMs worldwide for critical precision parts manufacturing. Contact us today for a FREE design consultation and to learn about our multi-tool discount program. Finding the right injection mold manufacturing company to be a part of your supply chain is a very important decision. Mold making companies that want to be on a preferred vendor list need to have a competitive edge, something that sets them apart from other mold making shops. OEMs today need to choose suppliers that can handle large projects, and delivery quality tools on time, regardless of the complexity.
Michiana Global Mold is an experienced injection mold making facility, supplying high-performing precision molds for over 52 years! We are experienced with complex designs for molding of critical components in various industries, including precision Automotive components. We employ expert mold design engineers, and journeyman mold makers with vast experience in all aspects of custom injection mold design. Michiana Global Mold utilizes the latest in technologically advanced equipment and software, using CAD/CAM software integrated with our milling centers. ISO Registered Mold Making Facility We are an ISO Registered mold making facility, that will partner with you from the beginning. Meticulously following a detailed checklist, we are able to identify any critical areas with precision tolerances that may be affected by mold flow or design. We can even assist with reverse engineering, enhancing your design by alerting you to potential issues prior to cutting steel and working together to obtain the optimum design for your application. We are then able to sample your parts and make any necessary final adjustments to your tool, delivering quality parts, on time. We can construct mold inserts, fully functional molds, mold compositions, over molds for insert molding, and tool adaptations including engineering changes. Contact Michiana Global Mold today to learn how our vast experience, knowledge, and technical capabilities will add value to your supply chain. We partner with our customers from the beginning, providing quality, precision molds for a wide array of applications over various industries. Michiana Global Mold is an ISO Registered injection mold construction supplier, providing quality class steel molds since 1952. Quick response and flexibility are required of tool and die makers today. Mold makers must continually strive to reduce production time while still ensuring a high level of quality, and all while providing cost reductions. With tight margins and high demand for quick turn-around, tool and die makers may be searching for the best manufacturing method to remain competitive.
Using an EDM machine (electrical discharge machine) along with a high-speed milling machine may provide assistance with on-time delivery. Certain manufacturing needs in a tool and die shop may require differing manufacturing methods. The design engineer should be aware of all available manufacturing technologies. Mold Manufacturing Products Require Differing Technologies Injection molds and diecast molds, forging dies, and deep drawing dies are the three main products of tool and die making. Deep drawing dies mean that the metal blank is drawn into a forming die with a punch. The drawing is considered to be deep drawing when the depth of the drawn part is greater than the part diameter. They all possess their own constraints regarding applicable technologies for mold production. Deep drawing dies have flat structures and materials that are best manufactured with milling. When producing forging dies, EDM is widely used due to the strength of materials used in production. Complete machining with milling is possible, however, with low depth and large concave radii. Milling diecast and injection molds is challenging due to ribs or webs, and small radii. Developing the combination of EDM and milling is necessary for economical mold production meeting tight tolerances. Utilizing the benefits of all production methods gives designers and mold manufactures options in mold manufacturing. Other considerations in deciding between EDM or HSM are high speed milling, the geometric constraints, and surface quality or subsurface damage of a tool. Of the utmost importance is the effect on the surface from either EDM or HSM, as related to the part specifications. Some parts may require a surface conducive to adhesion from certain coatings or lacquers, and the finish of the tool plays an important role in the surface finish of the molded part. Employing skilled design engineers and journeyman mold makers, we have the experience to utilize the latest technology with a full line up of modern EDM and high-speed milling centers. This gives the most benefit to our customers in providing the most efficient, and cost effect mold manufacturing, with high quality tools and on time delivery. Michiana Global Mold is an experienced mold designer and manufacturer, supplying high performing precision injection molds since 1952. We are an ISO registered mold shop, adhering all processes to our strict quality policy, ensuring total customer satisfaction. Michiana Global Mold is experienced in all aspects of tool and die making, including injection molds and brass forging dies. Contact us today for a free design consultation, and learn how to save up to 40% on your next injection mold requirements. The ejection system is a very important part of an injection mold design. The ejection system must correspond to the stroke of the press, and work in perfect harmony with any auxiliary equipment utilized in the press. The ejector pins must also be placed where they will eject the part without causing any damage to the part. This can be tricky with small intricate molded product, it may be difficult to find the right angle to eject an oddly shaped part with critical dimensions or thin walls. In some cases, lifters must be used just for this purpose, to eject the parts properly and without causing damage. If lifters are required this must be apparent prior to building the mold. This is where an experienced mold designer will determine the best placement of any required lifters in the ejection system. A lifter is part of the ejector plate, activated during ejection. They are usually angled and slide up when required during ejection, allowing the part to mold all dimensional features properly. If auxiliary equipment is attached to the press such as sprue pickers, the ejector system, whether it includes lifters or not, must always accommodate any automated auxiliary equipment. Sprue pickers are automatic robots that reach into the mold when it opens to grab the sprue, also called the runner, and move it out of the way usually dropping into a bin or grinder to grind up and re-use the material. A two-stage ejection system is sometimes used with a robot grabbing the sprue, and the parts falling onto a conveyor or into a bin below. Utilizing the latest technology with CAD/CAM software, Michiana Global Mold can design your complicated precision injection mold with an ideal ejection system. We have experience designing and building precision molds requiring complex ejection systems, utilizing lifters, and accommodating the injection molder’s press specifications. Contact Michiana Global Mold today for an expert mold design and injection mold construction with quality steel and components. We have been an integral supplier of injection molds for over 50 years, employing skilled designers and journeyman mold makers. Michiana Global Mold is registered to ISO9001:2015, adhering all processes to our strict quality policy. Contact us today for a free design consultation of your next mold building project. Choosing the right injection mold supplier for your project is an important decision. Every injection molding project begins with a quality constructed injection mold. You need to choose a supplier that can handle your project, no matter the complexity or precision tooling required. At Michiana Global Mold, we are experienced in constructing quality precision molds, taking into account all necessary design considerations from the beginning resulting in a perfect mold for your application. Michiana Global Mold employs expert mold designers, utilizing the latest in technological advancements with CAD/CAM (Computer Aided Design / Computer Aided Manufacturing) Software. Download our FREE Book on Design Considerations for Various Molds. Michiana Global Mold will partner with your business from the beginning, providing you with options that will give you the best value for your mold construction project. We use CAD/CAM along with mold flow analysis when necessary, to pinpoint any critical dimensions before cutting steel. We have full in-house design capabilities with expert experience in all facets of design construction and machining. We can construct fully functional molds, mold inserts, over molds for insert molding, mold compositions, and adaptations including engineering changes. We have the skill and experience to produce best in class automotive injection molds, satisfying even the most stringent of quality requirements. As an ISO Registered tool shop, we are familiar with following documented guidelines, providing excellent workmanship to meet precision tolerances. We will identify problem areas before they would become a problem. Our staff includes journeyman moldmakers that have vast experience with tool construction for a wide array of industries. We have the knowledge required to provide precise, technical tools for various applications including those required in the automotive industry, consumer electronics, medical, and military / ordnance requirements. Contact Michiana Global Mold today to learn how our vast experience, knowledge, and technical capabilities will add value to your supply chain. We partner with our customers from the beginning, providing quality, precision molds for a wide array of applications over various industries. Michiana Global Mold is an ISO Registered injection mold construction supplier, providing quality class A steel molds since 1952. Industries That Require Precision Parts Manufacturing
Precision Parts Manufacturing supplies several industries with critical components. Aerospace, Automotive, Military / Ordnance, Medical and Consumer Electronics are just a few of the areas where a precision parts molder is a valuable supplier. The majority of molded critical components are made by the precision injection molding process, using thermoplastic resins. Engineering Resins are a group of thermoplastic materials that combine great strength with light weight to be a desirable material in a wide range of conditions, and still be economical. Precision Molding Process The quality of a final critical component from the precision parts manufacturing process depends on several parameters. Three factors that greatly impact the quality of a precision part are the manufacturing parameters, the material characteristics, and the mold design. Manufacturing Parameters When a precision injection molder is presented with a part print, they must determine the best size press to run the parts in taking the press attributes including tonnage, and clamping pressure into consideration. They must also consider the type of tool to build, and the molding conditions that would yield the most optimum processing conditions. Auxiliary equipment must also be considered. When a precision molder can use automation such as sprue pickers and conveyors, they can maintain a consistent process and reliably produce quality accepted parts. Determining the optimal parameters for the molding process is necessary to ensure consistency and reliable product quality. Material Characteristics When choosing the best material for an application, engineers must consider all characteristics of several different thermoplastic resins to choose the most appropriate resin that will meet the strength and durability demands of the functionality of the part. It is also important to maintain a strong relationship with your resin suppliers. Most polymer supply companies have material experts on hand ready and willing to assist with new information, suggestions and/or simulations. Mold Design A quality precision injection molded part requires a quality precision injection mold. A flawless mold is the key to reliably and consistently producing parts to customers’ specification. In most cases, the injection molder will design the mold based on the part print received by the customer. Molds for manufacturing precision parts can be complex and require the skills of a journeyman mold maker. It is helpful to have journeyman mold makers in-house that will lead the tool design and communicate with the customer’s engineers during the design phase. CAD software and mold flow analysis is used, which is an indispensable tool for any plastic injection molded part. Mold flow analysis is an indispensable component of any plastic injection molding design project. Quality Procedures of Precision Parts Molders Precision Injection Molding for demanding industries requires the molder to follow necessary quality procedures. Meeting ISO9001:2008, and compliant to TS/ISO16949, and AS9100 standards and practicing them daily is necessary for success with precision parts manufacturing. |
Archives
August 2017
Categories
All
|