Mold Design Service

Designing plastic parts is a complex task involving many factors that address a list of requirements of the application. "How is the part to be used?" "How does it fit to other parts in the assembly?" "What loads will it experience in use?"

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Mold Design ServiceInjection Molding Plastics

Plastic Mold Design Services Enhance Manufacturability & Cost-Efficiencies

Designing plastic parts is a complex task involving many factors that address a list of requirements of the application. "How is the part to be used?" "How does it fit to other parts in the assembly?" "What loads will it experience in use?" In addition to functional and structural issues, processing issues play a large role in the design of an injection molded plastic part. How the molten plastic enters, fills, and cools within the cavity to form the part largely drives what form the features in that part must take. Adhering to some basic rules of injection molded part design will result in a part that, in addition to being easier to manufacture and assemble, will typically be much stronger in service. Dividing a part into basic groups will help you to build your part in a logical manner while minimizing molding problems. As a part is developed, always keep in mind how the part is molded and what you can do to minimize stress.

Our plastic mold design services have renewed multiple projects after our engineering department diagnosed and provided solutions for improper mold design.

We pride ourselves in helping the customer by becoming involved early in the plastic mold design process. Getting involved early helps prevent design and quality challenges before the molding process even beings. It also helps prevent costly and sometimes catastrophic end-use product failures.

Applications

Plastic injection molding is the preferred process for manufacturing plastic parts. Injection molding is used to create many things such as electronic housings, containers, bottle caps, automotive interiors, combs, and most other plastic products available today. It is ideal for producing high volumes of plastic parts due to the fact that several parts can be produced in each cycle by using multi-cavity injection molds. Some advantages of injection molding are high tolerance precision, repeatability, large material selection, low labor cost, minimal scrap losses, and little need to finish parts after molding. Some disadvantages of this process are expensive upfront tooling investment and process limitations.

Polymers Best Suited for Injection Molding

Most polymers may be used, including all thermoplastics and some elastomers. There are tens of thousands of different materials available for injection molding. The available materials mixed with alloys or blends of previously developed materials means that product designers can choose from a vast selection of materials to find the one that has exactly the right properties. Materials are chosen based on the strength and function required for the final part; but also each material has different parameters for molding that must be considered. Common polymers like nylon, polyethylene, and polystyrene are thermoplastic.

Injection Molding Machine:

Injection molding machines, also known as presses, consist of a material hopper, an injection ram or screw-type plunger, and a heating unit. Molds are clamped to the platen of the molding machine, where plastic is injected into the mold through the sprue orifice. Presses are rated by tonnage, which is the calculation of the amount of clamping force that the machine can exert. This force keeps the mold closed during the injection molding process. Tonnage can vary from less than 5 tons to 6,000 tons, although the higher tonnage presses are rarely used. The total clamp force needed is determined by the projected area of the custom part being molded. This projected area is multiplied by a clamp force of from 2 to 8 tons for each square inch of the projected areas. As a rule of thumb, 4 or 5 tons/in can be used for most products. If the plastic material is very stiff, it will require more injection pressure to fill the mold, thus more clamp tonnage is needed to hold the mold closed. The required force can also be determined by the material used and the size of the part with larger plastic parts requiring higher clamping force.

Our Equipment List

Equipment Name Model Max.Stroke/Precision Quantity
CNC DMG-Mori Seiki NV5000(20000RPM) 730*510*510mm 2
CNC DMG-Mori Seiki NVX7000 HSC( 20000RPM) 1540*760*660mm 1
CNC Mikron HSM500(42000RPM) 500*450*350mm 1
CNC Mikron MILL S 800(42000RPM) 800*600*500mm 1
CNC FANUC a-D14MiA(24000RPM) Robodrill 500*400*330mm 2
CNC FANUC a-D21MiA(24000RPM) Robodrill 500*400*330mm 2
CNC CNC1050(15000RPM) 1000*600*500mm 3
CNC Yong Jin NCV56AM(12000RPM) 500*450*350mm 1
CNC SHANG SHANG JINGJI(26000RPM) 750*600*350mm 4
CNC Aikan 850(8000RPM) 800*500*500 1
Mirror EDM Agie Charmilles F0 350 SP 350*300mm(0.005mm  precision) 5
Mirror EDM Agie Charmilles Form20 400*400mm(0.005mm precision) 2
Mirror EDM HSPK 750*750mm; 650*650mm 4
EDM Wire Cut Agie Charmilles CUT20P 350*250*250mm 4
EDM Wire Cut Agie Charmilles CUT30P 600*400*350mm 3
EDM Wire Cut Agie Charmilles CUT200P 350*220*220mm 1
Fitting Machine ShunXing 1200KN 1400*1100mm 1
Grinding Machine Japanese Hyfair 0.001mm 3
Grinding Machine HF-618 450*150*300mm 6
Grinding Machine KGS306AH 650*600*300mm 1
Grinding Machine OKAMOTO Grind-X Acc350ll 0.002mm 4
Lathe CH6140A-1000 750*1000*1500mm 1
Milling Machine G0003 950*400*400mm 6
Projector SVM25011 300*100cm 1
Projector Seven Oceam Projector (SVM 403011) 400*300mm 1
CMM ZEISS 500*700*500mm 1
CMM HEXAGON-SEREIN-FUNCTLON1086 800*1000*600mm 1
CMM HEXGON-Global Classice SR05.07.05 500*700*500mm 1

Mold Design Services For Thin Wall Packaging Parts

Thin wall 500ml Food Container with 4 cavities hot runner mold tool.

Food container details:
Weight: 13.0 gram
Wall thickness: 0.45--0.6mm (0.0177 inch)
Material: PP homo polymer
Cycle time: 3.9--6 seconds (Fall freely)
Ejection type: 4 individual stripper plates
Annual production capability: 28 million (4 cavities)

Thin wall Disposable Rectangular 750ml Tub 2+2 Stackmold

Part weight: 22.5 grams
Wall thickness: 0.55-0.6 mm (0.022 inch)
Material: PP homopolymer
Cycle time: 6.6 -8 seconds (By robot )
Hot tip hot runner
Annual production capability: 17.5 million (4 cavities)
Machine clamp requirement: 300T

Thin wall Disposable Rectangular Lid 2+2 Stackmold

Part weight: 12.4 grams
Wall thickness: 0.5-0.55 mm (0.02 inch)
Material: PP homopolymer
Cycle time: 4 -6 seconds (Fall freely)
Hot tip hot runner
Annual production capability: 30 million (4 cavities)
Machine clamp requirement: 250T

Thin wall Disposable Rectangular Lid 4+4 Stackmold

Part weight: 12.--15 grams
Wall thickness: 0.5--0.6mm (0.02 inch)
Material: PP homopolymer
Cycle time: 5--6.5 seconds (robot takeout)
Hot tip hot runner
Annual production capability: 45 million (8 cavities)
Machine clamp requirement: 500T