Injection molding is one of the most common manufacturing methods to produce thin-wall engineered parts. Development of molds that produce high quality parts is a talent that develops with experience. Due to the time and effort required to develop a good set of tooling, it is not unusual for manufacturers to seek out injection molding machines that will be compatible with their molds, rather than trying to redesign molds to work on specific machines. As designers of injection molded products you are probably well aware of design best practice. What you may not appreciate is the important contribution a well designed mould tool can make to the new product development process. The wrong decisions taken at the critical early stage of a project will add cost and time to mould tool design, manufacture and maintenance, put pressure on product launch dates, and, of course, adversely affect product manufacture and in-use performance.
I am a moldmaker turned mold designer and have been using Unigraphics for about 5 years. We completely silid model all of our molds and use the UG cam package for all of our cnc machining. Moldwizard saves a lot of time by importing standard components.
Be aware of gate orientation when gating into the thick regions to avoid jetting. You can prevent jetting by placing the gate so that the flow is directed against a cavity wall. When creating a 2D part drawing for quotation, designers should focus on the annotations to communicate the final part design intent to the quoting suppliers. At minimum, the following items should be shown or specified for a successful process: • Finishes for cavity and core according to Society of the Plastics Industry (SPI) standard, textures type and number • Visible or cosmetic surfaces and non visible surfaces • Material type, manufacturer, and grade number or flexural modulus required • Material color, Pantone number, or other paint manufacturers • Tolerances as per SPI Standards and Practices of Plastics Molders and critical dimensions and tolerances to be held • Suggested gate location • For a cosmetic or mechanical part, where ejector pins, weld or flow lines are not acceptable • Acceptable location for part and revision number, molding date insert • Acceptable flatness deviation • With which parts and how this part will be assembled or mated 3d printing service Chandigarh kochi - fdm technology
It is a good practice to involve all suppliers early in the process to identify and discuss resin candidates, for instance, with material suppliers. The same is true for contacting moldmakers and molders. Having everyone involved early will usually help the new design evolve into the best and most cost- effective with reduced tooling costs. In addition, it may result in eliminating mold complexity, reducing parts count, and facilitating easier part assembly. Another rule of thumb is to use suppliers’ technical resources as part of the design team. The following are a few suggested points to be included in new mold RFQ documentation: • Detailed mold design drawings featuring a full bill of materials, assembly drawings, and detail drawings for each mold to be submitted for review approval. • Mold to have an identification plate bearing the following info: part number, mold number, and “Property of XYZ Company.” • Type of mold required; 2 plates, 3 plates, and hot runner • Type of mold steel and hardness for mold base, plates, and core/cavity inserts • Expected yearly part volumes requirements • Type of mold classification required according to SPI Standards (101, 102, 103) • Mold life and number of cycles guarantee • Mold maintenance responsibilities • Mold insurance Design guidelines for subtractive rapid prototyping First Cut Prototype uses multi-axis CNC machining to produce functional parts from solid blocks of real plastics. Unlike additive processes that can create geometries of almost unimaginable complexity, subtractive rapid prototyping is limited to shapes that can be cut from a block of solid material using CNC milling machines. The First Cut Prototype process currently uses three-axis CNC mills capable of producing parts within a 10-in. by 7-in. by 3.75-in. deep envelope. The maximum depth that can be milled from either side of the part is two inches. Parts smaller than 0.25-in. by 0.25-in. by 0.25-in. are hard to hold while machining. Very small features, particularly if they are deep, may not be machinable. Recessed text should have a minimum stroke width of 0.020 in. The spacing between characters on raised text should be 0.020 in. or greater. Interactive FirstQuotes® will present the available list of thermoplastics and will identify radiuses and features that cannot be machined.
I agree with vexmatech about setting the design intent early. In the past I've modelled parts for 3D printing but the client has later asked for them to be moulded, only to find that they're not suitable for this process. I'm still learning a lot about moulding but for me some of the most the important requirements are: 1. Draft angle of at least 1 degree on all vertical walls (to allow the parts to be removed easily from the mould, especially after shrinkage caused by cooling). 2. Try to maintain a constant wall thickness, or at least have a gradual transition between differing thicknesses. 3. Try to avoid undercuts. These can be made with specialist or moving moulds but it makes them more complex and expensive. Undercuts can often be designed out with a little thought. 4. Avoid very thick areas of material as these can cause sink marks or warping during cooling. I'd love to hear any more tips anyone has, or any corrections to mine!
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