Mold making is a process of making injection molds that are used to produce hundreds of or thousands precision plastic parts. As one of the most significant production investments, it is critical that the molds are made with a great deal of accuracy. Modern mold making requires extreme precision to ensure that parts can be mass-produced with repeatable accuracy.
This perfection is also required in the creation of the tools used to manufacture, hold, or test products during production. Quality precision molds are built to last and represent an essential investment for any company. Variables that can impact the cost of the plastic injection mold include:
. Core Metal
.Number of Cavities
.Mold Base
.Core/Cavity Machining
.Part Complexity
What Has Changed?
Plastic injection molding first gained prominence during the 18th and 19th centuries. With the Industrial Revolution at its peak, toolmakers had to do most everything by hand. Forming tools, heat treating, sharpening, machining metal, and drilling out the design by hand required a significant time commitment.
Due to the uniqueness of anything made by human hands, conformity problems often arose, and no two molds were precisely the same.Now, Computer Numerical Controlled (CNC) milling machines offer so many kinds of tools for cutting that the simple term and concept of “mold making” no longer covers the full gamut of the current capabilities. Today’s technology enables the fabrication of items with much more accuracy and range than ever before. The process is more precise than manual machining, and can be repeated in exactly the same manner over and over again. Because of the precision possible with CNC Machining, this process can produce complex shapes that would be almost impossible to achieve with manual machining.
The use of CNC machines not only speeds up the process but also offers a wide degree of flexibility. Computers can often be programmed to work overnight, providing around-the-clock production. Using computer-generated inputs, CNC machining are able to deliver precision, accuracy, and levels of consistency that manual machining could never before offer.
Working with Jingwei molding
Jingwei molding provides innovative manufacturing solutions that include mold design, mold building, and high-volume parts manufacturing. We are world renowned for the production of injection molded components of the highest quality and precision at highly competitive prices. From concept to completion, we provide all of the necessary resources to promptly and accurately complete your project. We serve industries ranging from consumer products and construction to auto , medical and pharmaceutical, and electronic and other custom plastic parts.
Jingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist. To learn more about our manufacturing capabilities and discover what makes us different, please visit our website: :jweimolding.com . If you're ready to jump into your next project with us, request a quote . No matter your need, contact us today so we can help your business face all of the changes and challenges of today's competitive marketplace.
2019年5月28日星期二
2019年5月22日星期三
8 Steps to Injection Molding Process Optimization
When making decisions about process optimization, tool engineers and process engineers work together to proactively identify and correct any tooling weaknesses, following these 8 steps:
1. TOOL FUNCTIONALITY EXAMINATION
Every aspect of the tool's mechanical functionality is assessed to make sure everything works as designed, using the material settings provided by the supplier of the material to be molded.
2. SHORT SHOT TESTING
Dynamic pressure loss and, in a multiple-cavity tool, cavity imbalance are determined and documented using sample parts. Also, the rheology curve (or viscosity curve) is established to indicate the best fill rate and pattern.
3. GATE SEAL STUDIES
Both the pressure curve and weight of the sample parts are observed to see if the gates fully seal and at what point sealing occurs.
4. SAMPLE PARTS EVALUATION/DATA RECORDING
All defects are examined and recorded, along with recommendations for any adjustments in the process or the tool in order to correct the defects. Likewise, data is recorded with regard to melt temperature, fill time, tool temperature, coolant flow, cycle time and pressure curves.
5. QUALITY CONTROL
The sample parts go to quality control for examination and documentation of their measurements, shot-to-shot consistencies and overall quality.
6. TOOL ADJUSTMENTS
Based on information gathered during quality control, necessary tool adjustments are made, and new sample parts are made.
7. NEW SAMPLE CREATION/QUALITY CONTROL TESTING
The new sample parts are subjected to the same quality testing and more adjustments are made, if necessary.
8. PROCESS PARAMETER/PERFORMANCE RANGES VERIFICATION
The quality testing and adjustments continue until all process parameters meet their performance ranges. Once verified, the tool is ready for use and the process is deemed optimized.
By leveraging scientific molding, experienced custom injection molding engineers understand each phase of development — from tool design and mold fill analysis to process monitoring and quality control. The result? The most efficient and robust process possible for manufacturing the complex injection molded plastic parts and products you need for complex applications from medical devices, electronic parts to automotive parts and other custom plastic parts.
Jingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist.Any questions,please feel free to contact us via info@jweimolding.com or visit us at :jweimolding.com
1. TOOL FUNCTIONALITY EXAMINATION
Every aspect of the tool's mechanical functionality is assessed to make sure everything works as designed, using the material settings provided by the supplier of the material to be molded.
2. SHORT SHOT TESTING
Dynamic pressure loss and, in a multiple-cavity tool, cavity imbalance are determined and documented using sample parts. Also, the rheology curve (or viscosity curve) is established to indicate the best fill rate and pattern.
3. GATE SEAL STUDIES
Both the pressure curve and weight of the sample parts are observed to see if the gates fully seal and at what point sealing occurs.
4. SAMPLE PARTS EVALUATION/DATA RECORDING
All defects are examined and recorded, along with recommendations for any adjustments in the process or the tool in order to correct the defects. Likewise, data is recorded with regard to melt temperature, fill time, tool temperature, coolant flow, cycle time and pressure curves.
5. QUALITY CONTROL
The sample parts go to quality control for examination and documentation of their measurements, shot-to-shot consistencies and overall quality.
6. TOOL ADJUSTMENTS
Based on information gathered during quality control, necessary tool adjustments are made, and new sample parts are made.
7. NEW SAMPLE CREATION/QUALITY CONTROL TESTING
The new sample parts are subjected to the same quality testing and more adjustments are made, if necessary.
8. PROCESS PARAMETER/PERFORMANCE RANGES VERIFICATION
The quality testing and adjustments continue until all process parameters meet their performance ranges. Once verified, the tool is ready for use and the process is deemed optimized.
By leveraging scientific molding, experienced custom injection molding engineers understand each phase of development — from tool design and mold fill analysis to process monitoring and quality control. The result? The most efficient and robust process possible for manufacturing the complex injection molded plastic parts and products you need for complex applications from medical devices, electronic parts to automotive parts and other custom plastic parts.
Jingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist.Any questions,please feel free to contact us via info@jweimolding.com or visit us at :jweimolding.com
2019年5月20日星期一
INJECTION MOLDING PROCESS STEPS
In broadest terms, the injection molding process can be broken into three steps:
1. PRODUCT DESIGN
Determining product objectives such as function, aesthetics, assembly, etc., and the requirements for accomplishing the objectives. A team of engineers specially trained in advanced methodologies such as Design for Manufacturability (DfM) is assembled to identify and possibly improve upon solutions to meet the particular project requirements — including the selection of materials for the final complex injection molded part and the tool.
2. TOOL DESIGN
Like product design, a thoughtful approach to tooling proves valuable. In addition to choosing the appropriate material for tool construction — hardened steel, pre-hardened steel, or aluminum — designing for proper gate location, draft, etc., is necessary to prevent costly project missteps.
3. MANUFACTURING
Production is the obvious goal of the step-by-step injection molding process. Achieving successful outcomes brings together the product and tool designs with resins that deliver to project needs (such as strength, heat tolerances, sterility, etc.) and moldability requirements including tight tolerances, uniform wall thickness, heating, cooling, and consistent repeatable cycling.
Jingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist.Any questions,please feel free to contact us via info@jweimolding.com or visit us at :jweimolding.com
1. PRODUCT DESIGN
Determining product objectives such as function, aesthetics, assembly, etc., and the requirements for accomplishing the objectives. A team of engineers specially trained in advanced methodologies such as Design for Manufacturability (DfM) is assembled to identify and possibly improve upon solutions to meet the particular project requirements — including the selection of materials for the final complex injection molded part and the tool.
2. TOOL DESIGN
Like product design, a thoughtful approach to tooling proves valuable. In addition to choosing the appropriate material for tool construction — hardened steel, pre-hardened steel, or aluminum — designing for proper gate location, draft, etc., is necessary to prevent costly project missteps.
3. MANUFACTURING
Production is the obvious goal of the step-by-step injection molding process. Achieving successful outcomes brings together the product and tool designs with resins that deliver to project needs (such as strength, heat tolerances, sterility, etc.) and moldability requirements including tight tolerances, uniform wall thickness, heating, cooling, and consistent repeatable cycling.
Jingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist.Any questions,please feel free to contact us via info@jweimolding.com or visit us at :jweimolding.com
2019年5月7日星期二
Top 15 Benefits of Plastic Injection Molding
Are you considering injection molding for the production of a current or upcoming plastic parts project? If so, you came to the right place. Injection molding is the ideal process for the production of a wide range of complex plastic components, and can benefit OEMs across many different industries. It’s consistent, affordable, and creates durable, high-quality plastic parts that can withstand just about any environment.
To understand how injection molding can really help today’s manufacturers, here are the top 15 benefits to utilizing the process :
1. ABILITY TO PRODUCE DETAIL/COMPLEX GEOMETRY
With the right tool design and a scientific molding approach to process optimization, injection molding can help manufacturers produce highly complex, detailed plastic parts.
2. HIGH-OUTPUT PRODUCTION
If you need to produce a large run of a single part/component, the injection molding process is ideal, as it ensures a consistent, repeatable design due to all parts being created from the same mold.
3. COLOR CONTROL
From clear to magenta, whatever color you need your plastic to be, injection molders can make it happen—even including multiple colors in one product when two-shot or overmolding processes are used.
4. FINAL FINISHES
Does your plastic part require a smooth finished appearance? Most parts come out of the mold with a smooth surface finish very close to their final look. Even if you aren’t going for a smooth appearance, you’re still in luck, as injection molding allows for many surface finishes that don’t require secondary operations. From matte finishes and unique textures to engraving, injection molding can provide the desired plastic parts you’re looking for.
5. COST SAVINGS
There are several ways that injection molding can help OEMs experience lower costs, from plastic part consolidation to overmolding. However, the number one way the process leads to low-cost outcomes is by significantly reducing the number of problems in, or increasing the moldability of, the part design before production starts—minimizing the need for expensive tooling changes down the road.
6. PRECISION
For OEMs with complex part designs requiring tight tolerances, injection molders can achieve designs accurate to within +/- .001 inches.
7. EFFICIENCY
If you partner with a sophisticated injection molder, you’ll be working with a team that likely has decades of experience under their belts. This means they know exactly how to optimize design and manufacture your components in the most efficient way possible, and focus on the design upfront to minimize problems down the road.
8. STRENGTH
The strength and durability of plastics has greatly increased over the years, and today’s lightweight thermoplastics can withstand even the most rugged environments. There are many types of engineering grade plastic to choose from, allowing OEMs to find exactly the right options for their applications.
9. PRODUCT DEVELOPMENT TIMELINE
From upfront design support to mold flow analysis software, injection molding can help OEMs achieve a shorter product development timeline, in turn speeding time to market.
10. ABILITY TO SIMULTANEOUSLY USE MULTIPLE TYPES OF PLASTIC
It’s not uncommon for complex part designs to require components made of different materials. Plastics expertise from the molder’s project engineers can help ensure that different polymers are compatible under all conditions to help reduce defects.
11. PRODUCT/PART CONSISTENCY
The production of plastic components for critical-use applications requires a consistent, repeatable process to achieve complex designs with tight tolerances. Injection molding helps ensure a consistent quality by repeatedly using the same mold for each part, and using scientific molding sensors to monitor the activity inside the mold.
12. FLEXIBILITY
Injection molding is all about flexibility. Whether we’re talking about the plastic properties themselves or your ability to be flexible in your color choices and material selection, injection molding gives OEMs lots of freedom with their design choices — especially when compared to metal.
13. LOW LABOR COSTS
Much of the injection molding process is automated by machines and robots, and controlled by a sole operator or mold technician. This keeps labor costs to a minimum and passes on savings to the customer.
14. LIGHT WEIGHTING
From the automotive industry to military applications, many OEMs are turning to plastic to help reduce the weight of their products. Today, high-strength, lightweight thermoplastics can be used to replace metal components with virtually no difference in strength or dependability.
15. REDUCED WASTE
Using plastic regrind can even help OEMs save on money and materials.
Jingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist.Any questions,please feel free to contact us via info@jweimolding.com or visit us at :jweimolding.com
To understand how injection molding can really help today’s manufacturers, here are the top 15 benefits to utilizing the process :
1. ABILITY TO PRODUCE DETAIL/COMPLEX GEOMETRY
With the right tool design and a scientific molding approach to process optimization, injection molding can help manufacturers produce highly complex, detailed plastic parts.
2. HIGH-OUTPUT PRODUCTION
If you need to produce a large run of a single part/component, the injection molding process is ideal, as it ensures a consistent, repeatable design due to all parts being created from the same mold.
3. COLOR CONTROL
From clear to magenta, whatever color you need your plastic to be, injection molders can make it happen—even including multiple colors in one product when two-shot or overmolding processes are used.
4. FINAL FINISHES
Does your plastic part require a smooth finished appearance? Most parts come out of the mold with a smooth surface finish very close to their final look. Even if you aren’t going for a smooth appearance, you’re still in luck, as injection molding allows for many surface finishes that don’t require secondary operations. From matte finishes and unique textures to engraving, injection molding can provide the desired plastic parts you’re looking for.
5. COST SAVINGS
There are several ways that injection molding can help OEMs experience lower costs, from plastic part consolidation to overmolding. However, the number one way the process leads to low-cost outcomes is by significantly reducing the number of problems in, or increasing the moldability of, the part design before production starts—minimizing the need for expensive tooling changes down the road.
6. PRECISION
For OEMs with complex part designs requiring tight tolerances, injection molders can achieve designs accurate to within +/- .001 inches.
7. EFFICIENCY
If you partner with a sophisticated injection molder, you’ll be working with a team that likely has decades of experience under their belts. This means they know exactly how to optimize design and manufacture your components in the most efficient way possible, and focus on the design upfront to minimize problems down the road.
8. STRENGTH
The strength and durability of plastics has greatly increased over the years, and today’s lightweight thermoplastics can withstand even the most rugged environments. There are many types of engineering grade plastic to choose from, allowing OEMs to find exactly the right options for their applications.
9. PRODUCT DEVELOPMENT TIMELINE
From upfront design support to mold flow analysis software, injection molding can help OEMs achieve a shorter product development timeline, in turn speeding time to market.
10. ABILITY TO SIMULTANEOUSLY USE MULTIPLE TYPES OF PLASTIC
It’s not uncommon for complex part designs to require components made of different materials. Plastics expertise from the molder’s project engineers can help ensure that different polymers are compatible under all conditions to help reduce defects.
11. PRODUCT/PART CONSISTENCY
The production of plastic components for critical-use applications requires a consistent, repeatable process to achieve complex designs with tight tolerances. Injection molding helps ensure a consistent quality by repeatedly using the same mold for each part, and using scientific molding sensors to monitor the activity inside the mold.
12. FLEXIBILITY
Injection molding is all about flexibility. Whether we’re talking about the plastic properties themselves or your ability to be flexible in your color choices and material selection, injection molding gives OEMs lots of freedom with their design choices — especially when compared to metal.
13. LOW LABOR COSTS
Much of the injection molding process is automated by machines and robots, and controlled by a sole operator or mold technician. This keeps labor costs to a minimum and passes on savings to the customer.
14. LIGHT WEIGHTING
From the automotive industry to military applications, many OEMs are turning to plastic to help reduce the weight of their products. Today, high-strength, lightweight thermoplastics can be used to replace metal components with virtually no difference in strength or dependability.
15. REDUCED WASTE
Using plastic regrind can even help OEMs save on money and materials.
Jingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist.Any questions,please feel free to contact us via info@jweimolding.com or visit us at :jweimolding.com
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