Computer aided design and manufacturing (CAD/CAM) is a necessity to injection mold makers around the globe. Injection molding today is complex with precision parts requiring tight dimensional tolerances. Thermoplastic resins provide many benefits over other materials and are being used in many critical applications worldwide, including components for the Automotive, Aerospace and Medical industries. Meeting these tight tolerances with complex injection molds requires the skilled use of CAD/CAM by an experienced injection mold design engineer.
CAD/CAM Delivers for Automotive Suppliers Automotive OEMs demand the best from their suppliers, and expect perfection with zero defects, continual improvement plans and even cost reductions. In order to satisfy the demanding requirements of the Automotive industry today, injection mold makers must operate in a lean and effective manner. Michiana Global Mold utilizes the latest in technological advancements with CAD/CAM design and mold making capabilities. Our skilled design engineers have decades of experience constructing custom, precision molds used in critical applications by OEMSs worldwide. Our design engineers can quickly identify problematic dimensional areas, and address all concerns with the customer via easy file sharing. Michiana Global Mold is experienced with UniGraphics, SolidWorks, Mold Flow Analysis, and various computer aided milling machine centers. Michiana Global Mold Offers Modern Injection Mold Making View Michiana Global Mold’s Equipment List and see why we are you one stop full service injection mold making and service facility. We currently have a full lineup of EDM and Milling centers with Charmilles, Hurco and Hansvedt to name only a few of the best names in mold making machinery. We have top of the line wire EDM, grinding, turning and drilling equipment, driven by technologically advanced CAD/CAM software and equipment. Combining advanced equipment with the skill and experience of our design engineers and journeyman mold makers, we are able to offer to you high quality precision tooling, on time and within your budget. Michiana Global Mold is an ISO Registered mold making facility serving OEMs worldwide with high performing, precision injection molds for complex components. Contact us today for a FREE cost estimate of your next injection mold project requirements.
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There are many benefits to working with an ISO Registered mold making facility, including quality product and cost savings to the buyer. ISO quality standards are recognized internationally as the set of quality standards for various industries worldwide to measure performance in their processes, which encompasses all business processes whether they be service or production related. Most suppliers to the Automotive industry must be registered to either ISO9001 or ISO/TS16949, providing uniform measurements to rate suppliers in a global economy.
Globally recognized quality standards give Automakers around the globe consistent quality procedures and standards to measure the performance of their suppliers, in quality and service. This makes the job of the purchasing agent more streamlined in choosing suppliers, and takes some of the burden off when qualifying suppliers to their supply chain. Most suppliers, even 2nd and 3rd tier suppliers, must be registered to ISO standards and provide a Certificate of Conformance. This gives peace of mind to Automakers around the world that their suppliers are adhering to their Quality Policy and performing continual improvement in all processes to remain competitive. Continual improvement projects that focus on increased cycle times, or reduced purchasing costs can be passed on to the Automotive customer, providing even more value as an ISO registered mold shop. Michiana Global Mold is an ISO Registered mold making shop, practicing continual improvement with top down management. We combine the latest in technology with our vast experience to provide the best options for injection molds, beginning with a detailed and thorough injection mold design. Our design engineers are the best in the business, with extensive experience using our CAD/CAM software and equipment. Our journeymen mold makers are accustomed to constructing complex injection molds for high volume, custom injection molding. We build the challenging tools that other mold makers shy away from. Michiana Global Mold is experienced with all types of molds, including insert cavities, cold and hot runner tools, shuttle molds, three-plate tools and any other mold type required. We meet tight tolerances and even tighter deadlines with quality injection molds, built right the first time. We provide sample parts and reports, and all required tool status reports. Michiana Global Mold offers discounts with our off-shore injection mold making partner, rebate programs for high-volume tool requirements, and FREE design consultations. Contact Michiana Global Mold today to speak with one of our skilled mold designers and learn how we can assist you with your next injection mold making project. We are an ISO9001:2015 Registered mold making facility with vast experience building custom, precision injection molds for demanding industries including Automotive. Thermoplastic engineering resins are the most common type of plastic resins used in the injection molding process. With many different types of plastic resins each with their own unique properties, it takes great care and consideration to properly design and construct a mold for use with thermoplastic resins. These highly useful polymer resins have varying properties of elasticity, resistance to temperature, corrosives, shrinkage and right down to the exterior finish such as a matte or a glossy finish.
Shrink rate is a very important property of thermoplastic engineering resins used in injection molding, as the cavities must be carved out to accommodate to this shrink rate. If shrink rate is not accounted for properly, a part may shrink too much after cooling and deviate from customer requirements. Knowing the cooling and shrink rate of the polymer resin used for any molding process is of the utmost important to the journeymen mold makers constructing the tool. Cooling rate is also important for the part to become completely solidified prior to ejection. Cooling rate must be configured into the injection molding cycle time, to ensure proper cooling and ejection without damaging the part. Each polymer resin will have a MSD sheet, Material Safety Data sheet along with material specifications clearly defined in each numbered lot of all thermoplastic resins. If working with a new material, a mold designer may prefer to use Mold Flow Analysis, for a computer simulated demonstration of how the plastic material will melt, flow and fill. Predicting the flow of thermoplastic resins prior to cutting steel is vital for accurate geometrical tolerances in the final product. Even with a material spec sheet which is necessary, nothing helps a skilled mold designer more than experience. Skilled mold design engineers are very familiar with the various properties of engineering resins allowing for precise mold construction with even the most specialty of molding resins. Michiana Global Mold is an experienced mold design and construction company, with vast experience with various thermoplastic resins used in injection molding. We employ highly skilled journeymen mold makers and expert design engineers to satisfy even the most demanding of customer requirements. We tackle the complex mold designs that other companies shy away from. For complex, precision molds that must meet tight tolerances, contact Michiana Global Mold today for superior mold design and mold making services. Contact Michiana Global Mold today to speak with one of our skilled mold designers and learn how we can assist you with your next injection mold making project. We are an ISO9001:2015 Registered mold making company with vast experience constructing custom, precision injection molds using various thermoplastic engineering resins. The gate is the mechanism that allows the plastic resin to flow into the mold, and every plastic part design must take careful consideration of the type and the location of gates. There are various styles of gating mechanisms typically used in injection molding, and each style will have an effect on the finished product. The style of gating chosen can affect the visual appearance of the part, the likelihood of warping or sink marks, and proper packing to meet dimensional tolerances.
Avoid Defects from Gate Location To avoid defects when processing, place your gate location at the heaviest cross section for maximum fill and packing to avoid sinks and voids. Experienced mold designers will also know when to consider adding a second gate location, which may be necessary in complex geometrical shapes to obtain proper fill throughout the part. The location of the gate should allow for automatic or manual de-gating, designed with the minimal length of flow path to minimize visual flow marks. In cold runner molds, the part is usually ejected attached to the runner and gate, de-gating removes the part from the runner system. Some processes include automatic de-gating with robotic arms that grab the runner out of the mold separating it from the part or parts. Gates in Hot-Runner Tools There are basically two types of gating systems used in hot-runner tools, where the plastic is injected directly into the cavity to avoid runners altogether. In a hot-runner tool, the gate may be either a thermal (or hot-tip) gate, or a valve gate. The hot-tip gate solidifies the resin at the tip nozzle immediately upon high pressure injection into the cavity, stopping the flow of plastic to the cavity. A valve gate is used when the plastic may not solidify completely upon injection, and therefore a valve slides over to cover the nozzle tip and stop the flow of resin. Either type is effective and cost efficient when used properly in a hot-runner system mold. Michiana Global Mold is experienced with constructing cold and hot-runner tools, with various styles of gating mechanisms involved. We are skilled with determining the optimum gate location for precision molds required to produce complex geometrical parts. Michiana Global Mold has been exceeding customer expectation with high performing injection molds since 1964. We have vast experience with all types of molds and mold base components. Contact us today for a FREE design consultation and to speak with one of our knowledgeable design engineers. 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. When an injection mold designer begins a development of the mold design, they must be aware of the environment in which the mold will run. This includes the size and type of press the mold will run in, the material used for molding, and any auxiliary equipment used for automation as the location of tie bars and cooling lines must not interfere with setting and running the mold.
Vacuum Conveying System A vacuum conveying system is an automated way to get the material into the press, with the right suction and force. Vacuum conveying systems suck the material while still in pellet from the gaylord or drum into the hopper of the press, providing a steady flow of material for continuous production. Vacuum conveying systems pull in a steady flow of material, and control the amount of material in flow to the press, and are also helpful with controlling the moisture content in the material. Sprue Pickers Aid Automation Sprue pickers are robotic arms that reach into the press and grab the runner when the mold ejects, instantly separating from it the parts which can then fall into a bucket or onto a conveyor belt. Some robotic sprue pickers reach in and pick up the runner then drop it either into a separate bin, or directly into a grinder where it can be ground up and reused as regrind material. Process Monitoring Injection molders use process monitoring systems to constantly monitor the press settings such as temperature and pressure, alerting an operator if the job begins to run out of specification. Some monitoring systems also provide material resource planning functions, tracking job due dates and material inventory for scheduling of jobs. All of the additional auxiliary equipment must function properly and work in conjunction with the mold when it opens and closes and operates on the tie bar. Michiana Global Mold has vast experience designing and manufacturing molds adhering to customer specifications and each unique environment. Contact us today for a FREE design consultation and to learn how we can assist. 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. Sourcing with an ISO Registered injection mold maker gives added value and valuable benefits with assurances of providing a consistent high quality product. Michiana Global Mold is an ISO Registered mold maker, providing top quality, high performance complex tools for the injection molding industry for over 50 years! We are experienced at designing injection molds for challenging parts that require tight geometric tolerances. Michiana Global Mold combines years of experience with the latest in technological advancements to deliver complex injection molds to manufacture parts within your specifications as precise as +/-.001”! Strict Quality Policy at MG Mold At MG Mold, following a strict Quality Policy is something we’ve done since 1943. Conforming to the globally recognized ISO standards only reinforces to our customers and partners that we hold the quality of our product, and your satisfaction in the highest regard. We are experts at constructing complex injection molds for critical components, satisfying the Automotive industry for decades as a core supplier. Our Continual Improvement projects result in cost savings to you, as we improve our efficiency and cycle times, while still providing superior long lasting, high performance injection molds. Our Advanced Quality Planning Procedures (APQP) include a thorough evaluation of all design considerations, no matter the type of tool required. From cavity inserts, prototypes, hot or cold runner tools, we conduct a thorough evaluation to develop the most appropriate design for and construction for your tool. Our use of CAD/CAM sophisticated equipment provides automated efficiencies that we pass onto our customer. You benefit from the years of experience and advanced computer systems utilized at Michiana Global Mold, in terms of a quality built tool producing the desired part within specification, delivered on time and most importantly manufactured properly the first time. We provide part sampling, and minor adjustments with our full-service mold construction, delivering a quality part on time due to a systematic approach and following our detailed checklist for designing diverse types of molds. Contact Michiana Global Mold today, a custom precision injection mold maker registered to ISO9001:2015. We follow a detailed checklist for every tool design, assuring your total satisfaction with a high performing, top quality injection mold. 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. 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. |
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