Constructing a prototype injection mold has many advantages to a successful launch of an injection molding program. Prototype tools give a molder a chance to try out a new design, prior to investing in a large multi-cavity full size injection mold. Some prototype tools are even constructed with just a prototype cavity, allowing for additional cavities to be developed later after perfection of the prototype.
Prototype tools are advantageous when using a new thermoplastic resin that the molder may not be familiar with. A prototype gives the advantage of learning how a new material will melt, flow and fill critical dimensional areas. A prototype also gives a molder a chance to try out a new design for a part that may have to fit into another larger assembly. Constructing a prototype tool will give the molder a chance to produce a prototype part to test out functionality, either in larger assemblies or even on an automated assembly line. Constructing a prototype tool is a very inexpensive way to test out new parts without an initial major outlay of cash. Prototype tools are typically constructed with less expensive material than a production tools, therefore are not made to stand up to high volume production but rather a few short production lots for sample testing. While production tools must be constructed with hardened steel, a prototype can be made of P20 or non-hardened steel, or even aluminum, as this is adequate to produce sample parts for testing purposes. Prototypes are used in many industries where an initial small investment into a mold for testing purposes is well worth it prior to constructing a high-volume production mold. Michiana Global Mold has vast experience assisting engineers and designers to achieve their dimensional goals with design assistance and Prototype Mold Construction. Contact us today for a FREE design consultation and to see how we can assist you with your project development goals.
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Prototype injection molds provide a chance to perfect the design of a molded product, prior to constructing a full size multi-cavity tool. This can be well worth the extra time and expense to make a smooth launch of mass production requirements.
A prototype mold is a very inexpensive method of testing out a new part design for proper functioning. Prototypes are usually constructed with less expensive material such as non-hardened steel or P20, or even aluminum, as the purpose is to mold sample lots of parts, not full production volume. A prototype mold usually has just one cavity, and this can be an easy to way to make sure a part will work as expected, before manufacturing a large multi-cavity tool. One part is all that is needed to verify the part’s dimensions and geometric tolerances. A prototype mold is used in industries where new model parts are always changing such as the Automotive industry. In some cases, new parts are used in existing assemblies, changing a design slightly but still using some existing components. In this case the new parts would have to be tested within the existing assemblies to ensure proper function. Prototypes give automotive design engineers a chance to try out a new part, and alter it if need be, to work properly with other new or existing components. Prototype Mold Advantages In addition to the flexibility to try out new part designs to verify part function, the biggest advantage of prototype tools is the low cost. Made with the less sturdy and less expensive material, a prototype tool cannot support production, it can however provide enough shots to produce sample parts for testing purposes. This is a very worthwhile investment, however, especially if you are uncertain about how the geometric design on one part will fit with your existing application, or if you just want to test part properties prior to building a production mold. With the low cost of prototype tools, it could be a very advantageous place to start here if you have any questions about a new part function. A prototype is also advantageous if the part is molded with a new resin, or a resin that the engineer is not familiar or experienced with. Since all thermoplastic resins contain varying properties for shrink rate, strength and durability, some prototypes are constructed to test the strength of a molded part in different materials allowing engineers to test out different resins. Michiana Global Mold has vast experience constructing prototype tools to customer specifications, giving you a quick turn-around time on sample parts for your testing purposes. We employ skilled design engineers and journeyman mold makers all with in-depth knowledge of prototype mold construction, and properties of varying resins. Michiana Global Mold has vast experience assisting engineers and designers to achieve their dimensional goals with design assistance and Prototype Mold Construction. Contact us today for a free design consultation and to see how we can assist you with your project development goals. 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. The Value of a Prototype Mold
Constructing a prototype mold for testing purposes can save you money by perfecting your part design prior to building a production injection mold. A prototype mold is the only type of mold that can be constructed of aluminum because is not intended for supporting any long term production requirements. A prototype mold is a good way for an engineer to see exactly how their new part will function in a real-life scenario, without the expenditure for a standard steel production mold. A prototype mold can cost considerably less than a Standard Mold, in some cases thousands or tens of thousands of dollars, while providing the benefit of developing your product to perform exactly as intended. Some other economical options for injection mold construction would be a MUD Unit, or what one if the project is certain but tiny details are still in question, you may want to build a standard mold with a prototype cavity, develop only one of a multi-cavity tool to perfect the part before constructing the remaining cavities. Versatility of MUD Units A MUD (Master Unit Die) Unit refers to a universal steel frame that fits into a press, allowing for an insert mold to slide in or out for quick changeovers. A MUD unit frame is extremely valuable for production runs that require just in time delivery, when the volume requirements do not dictate a standard mold expenditure. The ability to quickly switch out insert molds reduces machine down time and labor costs. Some molders prefer to use MUD units on jobs that run in the same material, allowing for smooth set up and production runs. This is an economical option that many molders can offer to their customers. Standard Injection Molds A typical standard injection mold is used in a horizontal clamping press, with two halves, an A & B side, that move together to form the desired production part(s) inside the closed mold. A standard mold will have either one or multiple cavities, the carved out area with specific precision geometrical shapes prepared to mold the desired part. In some cases, an engineer may be certain of needing an 8-cavity standard mold for high volume part production, but may want to perfect the design prior to constructing all cavities. Michiana Global Mold has vast experience constructing prototype tools, insert tools for MUD units, and prototype cavities in multi-cavity tools. Michiana Global Mold has been a superior supplier of high quality plastic injection molds for various industries including automotive, consumer electronics, medical and defense, for over 50 years. We are an ISO9001:2015 Registered mold builder, maintaining high customer satisfaction through continual product and process improvement. As their name suggests, stack molds include several molds attached to the machine so that multiple levels (or faces) can be produced at one time. Even if only two final products are made at a time, it will reduce the amount of time required to produce the same number of products nearly in half. This particular mold system can also be used to make assemblies with multiple components and a series of parts within a single family.
Components and Process The machine must be set up with the stack molds all connected to the injection area. These molds almost always use the hot runner process. You can set them up to create between two and four molds at a time, although the more molds stacked, the more floor space needed for production . Things to Consider Consider these points :
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