Keys to Successful Mold Making

The key to a successful and precision part depends on the quality of its mold, but building a reliable, long-lasting mold can take a considerable amount of time — and requires a great deal of accuracy. Also, molds are often one the largest capital investments in a project, so it’s critical that tooling
is built right the first time around. This is particularly important in high-volume injection molding projects, where molds can be extremely complex.
Below are some important factors to keep in mind when building a mold to ensure optimal quality and reliability.
What Makes a Good Mold?
A high-quality, precision-engineered mold that is built to last can be an excellent investment for your company. The best plastic injection molds feature all of the following characteristics:

1. Good design and engineering
2. High-quality stainless steel mold bases and cavities for optimal performance and durability
3. Manufactured on modern equipment with the capability for precise machining
4. Accurately crafted with attention to high standards and tight tolerances

How Does Our Factory Make Molds?
To create a mold, we reverse engineer a design from a supplied part or create a mold based on the customer’s drawing or CAD file. To craft the tool, the team then utilizes EDM equipment, CNC mills, lathes, and grinding machinery. Many of our designers started out as toolmakers, so they fully understand the intricacies of the process, from start to finish.
Custom Mold Making With Jingwei Industry
The Jingwei Industry has been building stainless steel molds for plastic injection molding projects for over 15 years, and we continue to work closely with every client to ensure high value and top-quality results. To learn more about our custom tool making and high-volume injection molding capabilities, please feel free to contact us via info@jweimolding.com or visit us at :jweimolding.com

New Plastic Product Development Process

Below we list a fairly standard sequence of steps that you will probably have to go through in the course of designing and making a new product.You can use it as a checklist to make sure you don’t overlook some vital step when planning the work, or when it has begun.
Step 1: Product Concept
This consists of basic sketches around your product idea. So ask yourself -what is your product and how is your product going to be used?
Step 2: Research
It is vital to research the current markets and demands. So you need to find out what is already on the market what is similar to your product idea? If there is a similar product, how is yours going to be better?
Step 3: Product design development
Using the information you have gathered from your research you can now develop your product designs. When you are designing your product need to answer the following questions:

• What is the function of my product?
• Will my product be able to withstand use?
•  Will the manufacturing process be easy to produce the final product? Does it contain multiple parts?
•  Will the process be cost effective? Can you still make profit after manufacturing your product?
•  Do you want your product to be of a high quality?
•  Can your product be maintained or will it break after one use?
•  Which material will your product be made from? This will depend on the use and the forces your product is expected to withstand.

Step 4: Research and development of the final design
This is the final tweaks to your drawings with dimensions and material selection so when you progress to step 5 you have a detailed drawing to work from.
Step 5: 3D model
Using 3D modelling software (CAD – computer aided design) you will get a computerised 3D model of your final product design. These designs will often highlight problem areas where the theoretical stresses and strains on the product will be shown. If there are problems now is a good time to address the design faults and revisit step 4.
Step 6: Prototype
A prototype of your design will be created using computer aided engineering systems.
Step 7: Prototype Testing
This is the point where you may have to go back to the drawing board when you test your prototype. Be critical – will your product function properly? If your product isn’t right, go back to Step 3 and re-develop your designs.
Step 8: Manufacturing
Once you are happy with your product prototype you can then manufacture your product! Manufacturing costs depend on complexity of your product, if there are multiple components, material selection, low batch product or high batch numbers. These factors need to be considered to ensure you will make a healthy profit on your end product.
Step 9: Assembly
The assembly of your product is vital – It is recommended that your product should have the minimum number of joins; this will not only spend up manufacture and reduce manufacturing costs it also makes assembly of your product quicker. So the overall costs of your product will be considerably less than a complex product.
Step 10: Feedback and testing
Test your final product with family, friends and focus groups. Again it is important to be critical of your product and listen to the feedback you get back from other people. This will help with any further product development.
Step 11: Product development
If your testing and feedback have highlight areas that need improvement, you will need to revisit your product development – most manufacturing companies would have flagged up obvious issues before you get to this stage so at this point you are just tweaking or you might be skipping straight to Step 12.
Step 12: Final Product
You now have your final product so you need to focus on your marketing campaign and how you are going to sell your product. Remember, the more you sell, the larger the manufacturing batches, the lower the cost of manufacture  means more profits!
Jingwei molding has more than 15 years experience in mold design and mold making. Any questions,please feel free to contact us via info@jweimolding.com or visit us at :jweimolding.com

4 top design considerations for the injection molding process

When you are preparing designs for the injection molding process, there are many factors to be taken into consideration. As a leading manufacturer of thermoplastic injection molded parts, we have the experience and knowledge of what makes a great design for the production of outstanding products.
As you begin the design process, there are important details to keep in mind. Plastic injection molded parts offer many advantages. The following are the top design considerations for the injection molding process.
1. Draft.This is the first and probably most important item to consider. Draft is what helps eject the part from the mold. Stuck parts, or parts that need to be forced out of the mold, are often damaged or distorted rendering them useless. To facilitate mold release, draft angles must be calculated during the design phase and customized for each part.
2. Wall thickness.When designing a part, minimum wall thickness must be considered. The thinner the wall the less plastic is required. Cycle times will be shorter because parts cool faster. Ideally, parts should be designed with the thinnest walls possible while still maintaining the integrity of the part.Uniformly thick walls offer the best possible outcomes in terms of reducing warping and maintaining quality. When wall thickness varies, filling the mold is more difficult and leads to stresses at boundary areas. If uniform wall thickness is not possible, a gradual taper is the best design option.
3. Wall strength.To strengthen the walls of the part, ribs are a vital consideration. During the design process, the thickness of the ribs must be in proper proportion to the walls. The height of the ribs, their orientation, and incorporating draft angles are aspects that must be taken into consideration when creating part designs.
4.Know your materials.  Material selection is one of the most critical considerations in designing your piece — it factors into many aspects of the process, including shrinkage factor, cooling time, flexibility and more. Different materials can have different minimum and maximum wall thicknesses, for instance, or can require different degrees of draft.
Although we have highlighted the top four items to consider when designing parts for plastic injection molding, there are many, many additional considerations. Jingwei molding has more than 15 years experience in mould design and making. Any questions,please feel free to contact us via info@jweimolding.com or visit us at :jweimolding.com

Plastic injection molding in the electronic industry

Electronics have come a long way in the past few decades,  plastic play important roles in the electronic industry. In many ways, plastic and electronics work hand in hand to produce the gadgets we have available today.

Plastics Are Often Present In Electronics.Plastic protects and insulates electronic products. Many electronics, from laptops to stopwatches, benefit from the protection of hard plastic electronics enclosures. In addition, plastic electronic components are very common in printers, handheld games, telephones, calculators, alarm clocks, and other electronic devices.

Insulation
Electronics are usually delicate and sensitive to water and harsh environments. Plastic enclosures protect the electronics parts from harmful elements. They also keep electrical currents from escaping, which helps to protect the user. Electric devices that plug into wall sockets, such as blenders and hair dryers, are encased in plastic for this reason.

Light Weight
When it comes to plastic electronics enclosures, the material is relatively light in weight for the durability and protection it provides. With electronics like laptop and smart phones, it is generally thought that sleeker and lighter is better. Plastic is the ideal material that can help accomplish this while still maintaining durability.

Less Waste
Because plastic goes into a mold, there is not much need for cutting off excess material. The mold predetermines the amount of plastic that will be needed. Other materials often need to be cut and fitted to get the right size and shape. Less waste means it is less expensive to produce.

Design Flexibility
It is often much easier and cheaper to produce a plastic electronic component into the perfect shape than it is with any other material. With injection molded plastic electronic components, the shape and size of the parts are almost limitless. It is possible to make one part where it took many pieces bonded together of metal or other materials. Each bond made the part weaker and more expensive to make. Using plastic drastically reduces the cost and increases the durability.

Custom Design
With technology that allows us to create molds of many shapes and sizes, we can create the tiniest details to the exact specification of the designer. This makes many ideas that were never before possible a reality. For example, without microchip molding, many of the technologies we depend on would not exist. Manufacturers are also incorporating designs and logos to their products that were expensive or impractical before.

Through plastic parts, enclosures, and microchip molding, plastic has helped the electronic industry reach new goals. Without plastic injection molding, electronics would not be mass produced like they are today. Plastics keep electronics evolving by making them practical and economical.

Jingwei industry has served the electronic industry for years develop and manufacture parts and has a team dedicated to providing you with the most cost effective solutions for design and manufacturing injection molded plastic electronic parts . visit us at :jweimolding.com Or contact us via info@jweimolding.com for your project.

Application of new plastics in the Automotive industry

Plastic parts made from the injection molding process are already a large part of the interior and exteriors of our cars. Ranging from bumper,door handles to steering wheels and light sockets and so on .

A new generation of plastics, polymers and compounds promise even more changes for these injection-molded parts. Here are a few instances of how these plastics will affect the automobile industry shortly.

Speed of Manufacturing

When measuring our current cars by volume, plastics make up about 50% of the vehicle. Because of this high percentage, the speed of production of the plastic pieces must be cost effective. Nowerdays,The new plastics allow for a faster processing time, which means that cars allow them to be manufactured quicker.

Increased Strength

The strength of injection molded parts is critical when considering structure and safety. Plastics are already strong, but they are being made stronger by the addition of other materials. Adding different types of fibers, it creates various effects on the strength of the plastic.

In the 1950s, manufacturers began to add short bits of glass fibers to plastics to create fiberglass. Since then processes and materials have grown to include advanced software that produce a fast-cycle time, glass-filled injection molding process. By using this process along with glass fibers, a plastic injection molding company can produce oil pans that are tough enough for SUVs and trucks.

Decrease in Weight

Another revolutionary development on the automotive side of injection molding is carbon-fiber reinforced plastic. Once these carbon-fiber composites are in full use, they will truly change the automotive industry.

These carbon-fiber compounds are lighter, and they will contribute greatly to reducing the overall weight of a car. According to the Department of Energy, these plastics could cause as much as a 50% reduction in the weight of a passenger car, which will in turn result in an improvement in fuel efficiency, as much as 35%.

All of these benefits will be passed down to consumers. The improved strength of the plastics will contribute to a safer and more durable car. A reduction in the total car weight will improve its fuel efficiency, saving consumers thousands of dollars in the cost of fuel during the normal life of most cars.

Jingwei industry has been helping automotive leaders for years develop and manufacture parts. We can help you make specialty parts or even custom nameplates. We would love to hear from you. Email or call us today.To know more on Automotive parts plastic molding. visit us at :jweimolding.com Or get a quote for your project.

4 Simple Tips on Cheap Injection Molding

Injection Mold is the biggest cost of manufacturing a plastic part.Cheap injection molding is essential especially when you have a limited budget for a new project.I’ll share 4 practical tips you can use to get your own cheap injection molding.

Tip 1: Make a simple part design
The more complicated you parts are, the more money you would spend. Keep the part design simple is the most important factor for cheap injection molding.

Tip 2: Let the mold maker know the mold lifeTo some customers, this might be difficult to decide. They would say: “well, I don’t know. It’s a new product, let the market decides” or “just give me the price, you don’t have to worry about the quantities”. Actually, an unsure mold life will surely make the injection molding not cost-effective. Why? The mold maker will have to use a longer mold life in case you need an increasing volume in future. So no mold life equals to longer mold life to injection molding manufacturers.

Tip3: Use a regular part color like black if possible, not white or clearBlack is a popular color, which applies to a wide arrange of plastic housings. If white or clear colors required, the injection molding manufacturers will have to use many resins to clean their machines first to avoid leftover colors. Also, a cleaner injection condition is required to avoid black spots. So if you want cheap injection molding, sometimes you would have to give up using white or clear colors.

Tip 4: Find a mold manufacturer at smaller size
When a manufacturing facility comes bigger, so does their profit, as they will have to pay off the factory rent, human expenses, and managing cost to maintain their running. However, these will make your injection molding expensive. So if you work with a small injection molding company, everything is based on lower pricing.

Conclusion:
Cheap injection molding is possible if you get it right. Make a simple part design, communicate with your injection molder. You will save your money for your project.

Jingwei industry has served the injection molding industry for over 15 years and has a team dedicated to providing you with the most cost effective solutions for design and manufacturing custom injection mold.Please visit us at :jweimolding.com or contact us via info@jweimolding.com.

Sports Equipment Apparatus Injection Mold Case Studies

At Jingwei, we manufacture millions of parts every year since 2009. We are proud to have earned a reputation for being one of the best in the industry, offering high-quality, low-cost solutions. When businesses have a need for high volume, high tolerance, intricate parts, they turn to custom plastic injection molding.Simple or complex, we provide the fastest, most affordable, Quick turn Plastic Injection Molding,CNC Machining,Plastic Parts Production for all industries.

Our experience creating plastic parts for a wide range of clients gives us a unique perspective on how to manufacture high-volume parts at the lowest possible cost. We serve a diverse group of industries including Sports equipment,Automotive Parts,Medical & pharmaceutical,Body Building Apparatus, Consumer Products and so on.

Large plastic parts -Our new three sets of Sports Equipment Apparatus Injection Molds:

.Jingwei industry has served the injection molding industry for over 15 years and has a team dedicated to providing you with the most cost effective solutions for design and manufacturing large custom injection mold.Please visit us at :jweimolding.com or contact us via info@jweimolding.com.

Body Building Apparatus injection mold Case Studies

At Jingwei, we manufacture millions of parts every year since 2009. We are proud to have earned a reputation for being one of the best in the industry, offering high-quality, low-cost solutions. When businesses have a need for high volume, high tolerance, intricate parts, they turn to custom plastic injection molding.

Our experience creating plastic parts for a wide range of clients gives us a unique perspective on how to manufacture high-volume parts at the lowest possible cost. We serve a diverse group of industries including Automotive Parts,Medical & pharmaceutical,Body Building Apparatus, Consumer Products and so on.

Large plastic parts -body building apparatus mold projects:

Jingwei industry has served the injection molding industry for over 15 years and has a team dedicated to providing you with the most cost effective solutions for design and manufacturing custom injection mold.Please visit us at :jweimolding.com or contact us via info@jweimolding.com.

Factors to consider when planning your custom plastic molding project

When planning a Projects involving custom plastic injection molding. You must be as specific as possible as you convey your project to the manufacturer in order to get an accurate quote and a reasonable timeline. It helps to have as much information upfront as possible. As you plan your plastic molding project, here are a few factors to consider and to discuss with your manufacturing team:

Cost Limitations

The cost of your project can vary depending on how much homework you’ve done, among other factors. Here are a few examples of cost considerations you should make well in advance:

• Design: Has your project already been designed? If so, have you already created a prototype? If no prototype, do you have your design in digital format or paper? The more production-ready you are when you approach the manufacturer, the more likely you are to have a lower cost.
• Material: Do you have a specific material in mind for your project? If you are trying to keep expenses as low as possible, let the manufacturer know that you are willing to use the lowest cost polymer capable of producing a quality product. More on that below.
• Color and texture: Both of these elements can influence cost. Color, for example, can get costly if you’re expecting a product with a glossy finish. The level of texture detail can also drive up prices, although you have multiple options to keep costs down.

What Material to Use

When determining the material to use, you have to consider both preference and necessity. You can’t always opt for the cheaper option because of the risk of damage either during production or after you’ve received the product. A product that cracks or must be recalled later on can cost your company a huge amount of money — especially when compared with the cost of using the higher quality material in the first place. Plus, don’t forget about your brand’s reputation.

Thorough testing for maximum service temperature, maximum stress and environmental effects ahead of time can help you avoid potentially costly errors. Your manufacturer can help you with each of these, so it’s important to give them that freedom rather than relying solely on datasheets.

Size of Production Run

Naturally, the larger the production run, the more you will pay for material costs. However, larger production runs can save you in the end, as the reduced cost to manufacture in bulk can negate the cost of materials. Speak with your manufacturer to determine when it makes sense to up the size of your production.

Production Speed

How quickly do you need your product? As with any manufacturing process, plastic molding has its time constraints based on the size of the production run, the level of detail and the quality of the end product.

Be upfront about your expectations, and let the manufacturer know how much wiggle room you have. Your manufacturer might be able to suggest a more efficient process or one that can significantly increase the quality.

Jingwei industry has served the injection molding industry for over 15 years and has a team dedicated to providing you with the most cost effective solutions for design and manufacturing custom injection mold.Please visit us at :jweimolding.com or contact us via info@jweimolding.com.

03/01/2017

The Importance of Thermoplastic Materials To Plastic Product Manufacturing

The Importance of Thermoplastics To Product Development & Material Efficiency：When it comes to plastic prototype development or plastic product manufacturing, it is useful to understand which material to use. Typically, there are two types of plastic materials: thermoplastic and thermosetting resin.

To make a long story short, thermoplastic materials can be melted, cured (cooled down such that they become solid), melted again, cured again, and so forth. There is a limit to the number of times this process can be repeated depending on the particulars of the given material but the point is that thermoplastic materials can be melted multiple times without significantly degrading the material.

Thermoset materials, by contrast can only be melted once. After a thermoset material cures, attempting to heat it again to its melting point would cause it to burn (rather than melt) the material. It is useful to think of a 2-part epoxy when trying to understand thermoset plastics. An epoxy, like a thermoset material, is liquid prior to setting. Once the resin dries, however, it is not possible to melt it again.

When it comes to plastic injection molding, it is easy to misjudge the importance of thermoplastic and thermosetting materials. By the way, both thermoplastic and thermosetting materials can be injection molded. The major difference, when using a thermoplastic or thermosetting material, applies after the injection molding cycle when the molded plastic solidifies. During the molding process, plastic is heated and injected into a metal mold. To get to the cavity of the metal mold, however, the molten plastic first needs to pass through an array of entry points and tunnels known as sprues, runners, and gates. The plastic cools within the mold cavity as well as inside the channels that lead to the mold cavity. The plastic that solidifies inside the channels is not the component or part of the final product. It is just a waste.

Now, what happens to the “waste” during plastic injection molding?

Thermoplastic Materials

If a thermoplastic material were used for injection molding, the waste could be recycled and used again. The solid plastic left within the sprues, runners and gates can be combined with the raw material that goes into the injection molding machine. The same thing can happen with the material from rejected plastic parts. All the waste plastic can be collected and recycled back to the onset of the process. This all sums up into higher efficiency, and eventually means, lower costs of the final product and better margin for the producer.

Thermosetting Materials

If a thermosetting material were used for injection molding, the solid plastic from the sprues, runners, and gates is simply a waste, which has no practical use whatsoever. This means that the cost of the final product will be more.

To conclude, thermoplastic materials offer some major benefits to plastic product manufacturers, consumers, and even the society，as such materials are recyclable that we are more responsibly stewarding our natural resources. Indeed, when it comes to plastic prototype development or plastic product manufacturing, the manufacturer should choose and use thermoplastic materials.

Jingwei industry has served the injection molding industry for over 15 years and has a team dedicated to providing you with the most cost effective solutions for design and manufacturing injection mold.Please visit us at :jweimolding.com or contact us via info@jweimolding.com.