Tag Archives: injection molding

Hot-to-Cold Injection Mold Making Experts

 

 

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.  

 

Injection Mold Making Technology

Injection molding is the mass producing of plastic parts with a steel mold, an injection mold, designed with cavities to mold the desired part.  Injection molding uses thermoplastic resins, also called polymers, typically in a raw pellet form, that melt and flow into the cavities in the mold, forming the part, then it is ejected once it hardens.  The time that it takes for the mold to close, plastic to flow into the mold, the polymer to set and eject upon mold opening is called the cycle time.  Injection molders are always looking for ways to increase the cycle time, as time is money and when you can mold a part faster, you can mold more per hour, per day and per week.  

A skilled injections mold maker will have the knowledge to design the mold with the most appropriate attributes to reap the best cycle time while still delivering the desired part to the customer specification.  Michiana Global Mold is accustomed to constructing complex, precision injection molds within +/- .001”, which is about the thickness of a human hair.  

Injection Mold Making Equipment

Injection mold makers are well familiar with the precision equipment used to carve out steel cavities, forming a perfect plastic part.   Computer aided design, and computer aided manufacturing (CAD/CAM) equipment is a key tool for designing a perfect tool.  The designers at Michiana Global Mold use Unigraphics CAD/CAM software to design the mold fit for producing a desired part.  This alerts the mold maker and the injection molder to any critical areas such as thin walls or a critical dimensional tolerance that must be met, prior to cutting steel.  

Milling machines, conventional EDM and wire EDM machines are a necessary tool, along with high speed CNC machines, drill presses and grinders.   Michiana Global mold, located in Mishawaka, Indiana with an offshore mold making facility in China, utilizes all of these mold making equipment tools, and more.  We have over 50 years of experience constructing complex tooling for demanding industries such as the Automotive industry where 0 ppm (parts per million) defects is the norm.  The key to a quality plastic injection molded part, is a quality injection mold.  

No one understands this better than Michiana Global Mold, your one stop shop for mold making and tooling services.  We do everything from constructing insert cavities and prototypes to full service high volume precision production tools.

Michiana Global Mold is Registered to ISO9001:2015, delivering custom injection molds to a wide array of industries demanding high volume long lasting performance with the best available pricing.  We offer rebates on multi-tool programs and discounts with offshore molding options.

Contact us today for a FREE design consultation, and to see how Michiana Global will provide value added services in your supply chain.

Offshore Injection Molds with Domestic Service

 

Michiana Global Mold, located in Mishawaka, Indiana, is a world class superior injection mold supplier with locations in the USA and China.  Our partnership with Modular Molds in China allows us to offer our customers offshore tooling with competitive prices, while still providing the same level of excellence they are accustomed to from our location in the United States.

 

Modular Molds is a large capacity, more than 40,000 square foot facility, with the capacity and resources to handle large and multi-tool programs.  This location has a primary focus on new tool builds, although any type of mold is available whether constructing inserts and cavities, or a partially completed full size mold to be finished in our Indiana location.   Our China location has the resources to provide full service injection mold making with additional resources to assure the highest of quality standards.

 

Modular Molds is also registered to ISO9001, just like our Indiana location, with both facilities following a strict quality policy with focus on continual improvement and total customer satisfaction.  Our China location offers use of the latest technology, such as:

  • Mold-Flow Analysis
  • Solid Works CAD software
  • Unigraphics (NX7.5)
  • AutoCAD
  • Reverse Engineering
  • PPAP Certifications

Both our Indiana location and our China location utilize the latest in technological advancements, with expertise in constructing complex, precision tooling.  Michiana Global Mold excels at custom mold making for tight tolerance, complex molds.  

The key to a quality part, begins with a quality tool.  At Michiana Global Mold, we offer the best in quality meeting our customer’s most demanding specifications, with quality tools delivered on time.  We offer offshore mold pricing with full domestic support.  All tools constructed in China undergo full inspection at our Indiana location prior to shipping.  We offer offshore molds with the same quality as our USA location, and discounts on multi-tool programs.  

Michiana Global Mold is your full service one stop shop for quality tooling and mold making services.  We have been manufacturing custom, precision injection molds for over 50 years, meeting and exceeding our customer expectations with quality tools delivered on time.  Contact us today for a FREE design consultation, and learn how Michiana Global Mold will add value to your supply chain.

Partner with an Experienced Injection Mold Maker

 

Injection mold making is a very critical, precision process that requires not only knowledge and resources, but also experience.  Experienced journeyman mold makers make all the difference in the world when it comes to creating a quality crafted injection mold versus a sloppy tool that barely makes the mark.   Having experience with building precision tools for a multitude of applications gives invaluable skill that cannot be learned anywhere else.  An experienced journeyman mold maker is a valuable component of the injection mold making process.

Experienced Journeyman Mold Makers at Michiana Global Mold

At Michiana Global Mold we employ a highly skilled design and engineering staff and master journeyman mold makers with in-depth knowledge and vast experience in designing and constructing precision, complex tooling.  We partner with you from the very beginning, coordinating on every aspect of your project with clear, transparent communication.  

Our experienced team draws on traditional methods, combined with our cutting-edge technology, to provide the best solution for your precision injection mold requirements.  Our large capacity facility in Indiana is equipped with conventional EDMs and wire EDMs, CAD/CAM engineering equipment, CNC milling centers, grinders, drills and saws.  

One of our knowledgeable staff can assist you in determining the best type of tool for your project, with the most cost-efficient method while not compromising precision quality.  Michiana Global Mold specializes in manufacturing tight tolerance, complex, precision tooling.  We have the experience and the resources to provide the perfect tool for your project, on time and within specification.  

Michiana Global Mold provides custom injection mold making for any required tooling operation.  We are experienced at manufacturing hot and cold runner molds, hot to cold molds, insert molds, shuttle molds and prototypes.  Our production molds are built with experienced craftsmanship, and only the best in quality components.  

Michiana Global Mold has been in business since 1964, serving the injection mold making industry for over 50 years!  We are an ISO9001:2015 Registered mold making facility with domestic and off-shore molding capacity.  We have the experience and the resources to provide quality molds for any molding application, and the resources to handle multi-tool packages within specification, and on time.  

Value Added ISO Registered Mold Makers

 

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.  

 

How a Prototype Mold Can Benefit Your Project

 

When engineers are designing new models of mass produced parts, you want to know if your new design will function as it should in the assembled product.  One way to verify your new part design is with a Prototype mold.

A Prototype mold can be constructed for less money than a full size standard mold to verify the functionality of the desired part.  Prototype molds are typically constructed with a less expensive material such as aluminum, non-hardened steel or P20, and usually contain just one cavity rather than multiple cavities, as only one part is needed to verify dimensions and part function.

This is advantageous in many industries such as the Automotive industry, where new model year automobiles combine new parts with current parts on the same vehicle.  In some designs, not all parts are updated or replaced yet all parts in any particular assembly must function perfectly together. A Prototype tool will give you the flexibility to test out and alter if need be, a newly designed part that will function to your specifications.  

Advantages of Prototype Molds

Since Prototype tools are constructed with less expensive, and less sturdy steel, it can only be used to produce short lots for testing purposes.  The material would not hold up for any large or standard production runs.  

This can still be a very worthwhile investment, however, especially if you are uncertain as to how the dimensions on one part will fit with your application, or if you just want to test it out prior to building the production mold.  Since the Prototype tools is quite economical, it could be advantageous to start here if you have any questions about a new project.

Michiana Global Mold has the resources, the experience and the experts on staff to build your Prototype tool to your specifications, allowing you to test your products prior to investing in standard mold bases.

Michiana Global Mold has vast experience helping engineers and designers achieve their geometrical and dimensional goals with design assistance and Prototype Mold Construction.  Contact Michiana Global Mold today to see how we can assist you with your project development goals.  

 

Ejection Systems and Lifters in Injection Molds

 

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.