Tag Archives: injection molds

Injection Mold Design for Engineering Resins

Thermoplastic engineering resins are the most common type of plastic resins used in the injection molding process.  With many different types of plastic resins each with their own unique properties, it takes great care and consideration to properly design and construct a mold for use with thermoplastic resins.   These highly useful polymer resins have varying properties of elasticity, resistance to temperature, corrosives, shrinkage and right down to the exterior finish such as a matte or a glossy finish.  

Shrink rate is a very important property of thermoplastic engineering resins used in injection molding, as the cavities must be carved out to accommodate to this shrink rate.  If shrink rate is not accounted for properly, a part may shrink too much after cooling and deviate from customer requirements. Knowing the cooling and shrink rate of the polymer resin used for any molding process is of the utmost important to the journeymen mold makers constructing the tool.  

Cooling rate is also important for the part to become completely solidified prior to ejection.  Cooling rate must be configured into the injection molding cycle time, to ensure proper cooling and ejection without damaging the part.  

Each polymer resin will have a MSD sheet, Material Safety Data sheet along with material specifications clearly defined in each numbered lot of all thermoplastic resins.  If working with a new material, a mold designer may prefer to use Mold Flow Analysis, for a computer simulated demonstration of how the plastic material will melt, flow and fill.   Predicting the flow of thermoplastic resins prior to cutting steel is vital for accurate geometrical tolerances in the final product.  

Even with a material spec sheet which is necessary, nothing helps a skilled mold designer more than experience.  Skilled mold design engineers are very familiar with the various properties of engineering resins allowing for precise mold construction with even the most specialty of molding resins.  

Michiana Global Mold is an experienced mold design and construction company, with vast experience with various thermoplastic resins used in injection molding.  We employ highly skilled journeymen mold makers and expert design engineers to satisfy even the most demanding of customer requirements.  We tackle the complex mold designs that other companies shy away from.  For complex, precision molds that must meet tight tolerances, contact Michiana Global Mold today for superior mold design and mold making services.

Contact Michiana Global Mold today to speak with one of our skilled mold designers and learn how we can assist you with your next injection mold making project.  We are an ISO9001:2015 Registered mold making company with vast experience constructing custom, precision injection molds using various thermoplastic engineering resins.  

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How to Source Injection Molds Overseas to Save Money

Figuring out how to source quality injection molds overseas with an injection mold maker in China can be a daunting task.  This endeavor can end up costing you more than it would be saving if not implemented correctly.  How do you know the quality of steel and craftmanship that this foreign company will put into making your molds?

When providing a competitive foreign quote depends upon landing that big contract or losing it, don’t leave this huge business endeavor to chance.  Work with a domestic mold making company who can provide overseas sourcing, and overseas pricing, with the same domestic quality and service your project demands.

Offshore Mold Sourcing from Domestic Provider

Michiana Global Mold is a mold making company located in the Midwest, USA, with a business partner in China to provide the same quality in complex injection molds as our domestic locations.  Both facilities are ISO registered, following a strict quality policy in mold design and construction.  With our offshore mold making partnership, we take care of all overseas communication and quality inspections for a hassle-free transition for you.  With one domestic customer service contact, you will have tool status updates and assurances of quality with on-time delivery.  

Our Chinese mold making partner, Modular Molds, uses only North American and German Steel to construct molds built to customer KPC’s.  We supply Initial Sample Inspection Reports (ISIR), with final inspection conducted at our domestic location for complete assurances to full print specification.  

Michiana Global Mold has more than 50 years of experience designing and constructing complex, precision tools.  We tackle the challenging molds that other mold builders shy away from.   WE are a full-service mold making facility providing prototypes, insert cavities, cold-runner and hot-runner tools,  three-plate tools and shuttle molds.   Download our FREE Guide to Sourcing Your Tools in China, and let Michiana Global Mold assist with your offshore mold sourcing project.

Michiana Global Mold is a leader in plastic injection mold making, serving the Automotive and various industries since 1964.  We offer high-quality, precision tooling from our domestic or overseas location, on time and to your specifications.  Contact us today to learn more about our offshore mold making capabilities.  

Plastic Injection Part Design with Ribs and Bosses

Ribs are often used to add strength and stiffness to plastic parts in critical areas or geometric designs where thin walls exist.  This makes the part stronger with added support but can also cause sink marks on the exterior side of the part, where the rib comes together to meet the main wall in the part design.  When using ribs to add support, remember the general rule that the rib should not be more than 60% of the wall thickness.  Adding ribs to an injection mold design will increase costs, and may require EDM processes.  

 

Working with an experienced injection mold manufacturer will give you the best value for your investment.  Skilled journeyman mold makers and experienced injection mold design engineers will have the best knowledge of where to place ribs for added support and how this will affect the tool design, and the cost.

 

Mold making companies today can provide you with a two-dimensional computer aided design to show you exactly how your injection mold will produce the required plastic part, and alert you to any problematic areas ahead of time.  

 

Bosses are a very common feature in many plastic parts, and comes from the word emboss, which means a raised stamp or design, standing out on the surface.   Bosses that are designed with too thick dimensions can cause sink marks similar to the use of ribs.  Utilizing the proper ratio of ribs to bosses a molder can reduce or eliminate unsightly sink marks caused by either feature.  

 

Ribs used to connect boss areas to a side wall can add strength while avoiding sink marks.  Sharp corners are another area where excessive stress can concentrate and adding small radii feature in this area can strengthen the corner and reduce excessive stress.

 

Michiana Global Mold is a full-service mold design and construction company, with vast experience in all types of molds.  We offer an ISO registered Quality System, state-of-the-art domestic mold building facility with off-shore partner, and decades of experience with precision, complex tooling.  Contact us today for a FREE design consultation and to speak with one of our highly skilled design engineers.

Determine Proper Ejection Method for Injection Mold Design

Injection mold design includes design of the optimum ejection system to meet part specification.  While ejector pins are most commonly used, there are other methods of ejection systems that are required in specific situations.

Ejector pins are round, and used to extend into the cavity to push the part out during mold opening so that the parts fall out or are pulled out by a robot.  Pins are adequate in most situations, although some part designs require pins along with an alternative method, or a different method altogether.

 

Ejector blades can also be used for ejection if the part design requires it, and these have more of a rectangular geometry.  Ejector blades are often used in designs where a thin wall exists, thus an ejector pin may damage the part with force or pressure applied in a critical area.

 

Ejection sleeves are tubular, and are ideal in areas of raised surfaces.  These raised surfaces are designed to assist with assembly in some designs, for example a raised hole at the end of a vertical part would be referred to as a boss.  Ejection sleeves provide 360° surface around the boss for easy part ejection with these types of part designs.

 

A stripper plate is another type of ejection system that consists of an entirely separate moving plate, that is designed to strip the part or parts from the core of the mold.  These are ideal in situations where you need to keep parts and runners separate, and are utilized in three-plate tool.  

 

Michiana Global Mold is a leading global injection mold design and construction company, with extensive experience in all types of ejection systems.  Our skilled mold designers and journeyman mold makers have extensive knowledge and experience with various types of mold construction.  We construct prototype molds with sample parts, cold runner or hot runner tools, shuttle molds, insert cavities and all aspects of injection mold design including engineering changes.

 

Michiana Global Mold was established in Indiana in 1964, serving various industries and specializing in complex, precision tools for the Automotive industry.  We offer a partner company in China with offshore mold making capabilities.  Both facilities are registered to ISO 9001 and follow strict quality management systems.  Contact us today for a FREE design consultation and to speak with a skilled design engineer.  

Precision Molds for Complex Part Designs

Injection mold designers must use careful consideration when designing a mold for a complex part design.   Intricate plastic injection molded parts may contain several critical areas that must be carefully designed to meet part specifications.  Parts that contain a very thin wall, for example, would be a critical fill area.  It takes expertise in mold design to fill a part completely without any overfill or underfill while still maintaining the integrity of such a thin critical dimension.

Critical areas should be identified on the part print, and throughout the entire mold design phase.  Sophisticated CAD/CAM software is used to develop a viable tool design given all part design specifications and other exterior design considerations such as the specified material and press size.  With a superior design software program like Unigraphics or SolidWorks, mold designers can develop the entire mold construction phase and test critical areas with computer simulation software.  This advanced quality planning phase is crucial to constructing precision molds to customer specification, and within the established lead time.

The part print will also contain specific information such as the resin used and the surface finish or texture required of the final part.  Any restrictions on knit or parting lines must be identified for proper gating.   It takes an experienced mold designer to implement a successful tool design and construction of a precision mold for injection molded parts with a complex design.

Download our FREE Book on Design Considerations for Different Molds, and contact us today to learn about our discount and rebate programs.  

Michiana Global Mold is an experienced injection mold design and construction company, supplying precision tools to various industries since 1964.  We are an ISO registered mold shop, satisfying the strict requirements of the Automotive industry with high quality complex molds.  Contact us today to speak with one of our knowledgeable engineers for a FREE design consultation.  

Full Service Injection Mold Making Tool and Die Shop

For full service tooling and mold making solutions, Michiana Global Mold offers a wide range of mold making and tooling capabilities.   Our niche, and one area of expertise is constructing precision, custom injection molds for complex part production using quality North American or German Steel with modern equipment and technology.  We meet the tight tolerances and fast deadlines of the Automotive industry, and are a valuable part of many other industrial supply chains.  

Our services include much more than building new injection molds, however, and as a full-service Tool and Die Shop we can offer a wide range of comprehensive tooling services.

CNC / EDM and Wire EDM Machining

With the latest in modern equipment, Michiana Global Mold uses four Charmilles CNC EDM Machines, a Charmilles EDM HD20, a full line of Hansvedt EDM centers, and a 3R and Erowa Tooling Package.  Our journeyman mold makers are experienced in the latest CNC EDM and Wire EDM Machinery and Equipment offering efficient tooling services.  

Grinding

MG Mold has over a dozen Harig grinders alone, in 6 x 12 or 6 x 18 with Grind All attachments, 1 Reid, 2 Boyer, and 2 Proth and 1 Chevalier Hydraulic Surface Grinders.   We can grind any surface area of any product meeting the most demanding of tolerances.  

Milling

With more than 30 different Milling centers, we have the capacity to provide full service for even multi-tool programs with quick lead times.  Our full line of milling centers include 1 Hwacheon 20,000 RPM High Speed Mill, 2 Fanuc Robodrill 20,000 RPM, over a dozen Hurco CNC Machining and Milling centers, 11 Bridgeport Milling Machines and various other milling machines fill our large capacity production area.

Sampling and Inspection

Michiana Global Mold will sample your tool in the selected material, providing first shots to your specification prior to tool delivery.   We provide the highest of quality and inspection services

Engineering Changes and Tool Adaptations

For all tooling processes, including Engineering changes and tool adaptations call on your one stop, full service tool and mold shop, Michiana Global Mold.

Michiana Global Mold has been supplying high-performance tight tolerance precision injection molds since 1952!  Contact us today for a  FREE no-obligation design consultation for your next mold making or tooling project.  

 

How to Source a Professional Mold Builder

What qualities are you evaluating when searching for a mold making company?  How do you qualify a mold builder as a preferred vendor?  You probably have a thorough, detailed and organized method of granting vendor approval, including a Quality audit.  As part of your formal process, some critical standards stand out as critically important over others, those would be:

  • Engineering Capabilities including modern and updated design software such as UniGraphics or Solidworks with 2D print and file sharing options
  • Quality of overall work performed including product quality of steel and components used in addition to high machining quality with modern and automated equipment, checked for accuracy
  • Delivery Performance – on time delivery ratio including capacity limits and premium delivery options

Engineering Capabilities

Not all mold making companies have kept up with the times and invested in the modern technology available to mold makers today.  With computer driven milling centers and workhorse EDM machines humming all day, the modern mold making shop must be well versed in the computer driven equipment.    Equipment today can hold several programs, constantly checking for accuracy while doing the work it is programmed to do.  Creating these programs takes skill and knowledge of the mold making process from an experienced mold design engineer.  

Quality of Overall Work Performed

Sourcing a mold making company that is registered to ISO9001 standards gives you added assurances that the quality of product and service will be to your specification.   ISO9001:2015 standards require measuring performance and implementing continual improvement projects, with quick response time to meet the overall goal – total customer satisfaction.  

Delivery Performance

As part of internal audits with an ISO registered company, delivery performance should have a positive ratio with an explanation for any late deliveries.  Mold making shops that use modern technology and perform advanced quality planning procedures delivery quality tools on time, with critical areas planned ahead.    

Top notch mold making shops like Michiana Global Mold provide all of these services, in addition to sampling and checking parts for accuracy prior to delivery.

Michiana Global Mold can assist you with your demanding supply chain requirements with modern engineering capabilities, registration to ISO9001:2015 providing on-time delivery of quality product.   Contact us today for a FREE design consultation and to learn more about our multi-tool discount program.