Tag Archives: mold design

Mold Design Consideration for Automated Molding

Injection molders today are using sophisticated, automated equipment aimed at molding high quality products with lean processes.  Automated auxiliary equipment is used to provide consistency in a process while reducing cycle times.  Each injection molder’s shop environment is different, and some equipment must be custom designed to work together.

 

An injection mold designer must be aware of the molding environment in which the mold will run, which includes the type of press, any auxiliary equipment used in the molding process and the location of tie bars and cooling lines.  This information is vital to a proper mold design to ensure that nothing will interfere with installation or operation of the mold.

Some Automated equipment that injection molders use are vacuum conveying systems, sprue pickers, robotic arms and conveyors, computerized quality inspection and rejection procedures, and automated packing procedures.

As any molder knows, reducing cycle time provides cost saving efficiencies that equate to increased profits to the bottom line.  Be sure to share with your mold designer any custom design requirements unique to your molding situation.  

Michiana Global Mold is experienced with the most challenging of mold designs requiring tight geometric tolerances with critical dimensions.  We construct molds used for any environment, with custom designed solutions provided with Unigraphics CAD/CAM Software, and Mold Flow Analysis if required.  

We are an ISO Registered mold making facility following a strict quality policy in all aspects of injection mold design and construction.  Michiana Global Mold has been a valuable supplier to many supply chains including to the Automotive industry for over 50 years.  We employ a highly knowledgeable and experienced staff, with skilled designers and journeyman mold makers.

Michiana Global Mold has in-depth knowledge designing and manufacturing injection molds that meet tight geometric tolerances.  Contact us today for a FREE design consultation and to learn how we can assist with all of your injection mold requirements.  

Advertisements

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.  

What are the Differences of ISO 9001:2015 and 9001:2008

ISO 9001 is a set of internationally recognized standards that provides a uniform way of measuring a company’s internal quality systems.  ISO was first introduced in 1987, and is administered by the International Organization for Standardization (ISO) headquartered in Geneva, Switzerland.  

The latest version of ISO9001:2015 is replacing the prior version from 2008, as a new standard is introduced about every seven years.  When first introduced in 1987, the standards focused on documentation, saying what you do, and how you do it.  Defining job descriptions, work instructions, and quality checks and balances was a big part of the initial introduction of ISO standards.  

The updated version that came next in 1994 enhanced upon “say what you do”, and added “say what you do, and do what you say” (and prove it).   Further documentation was required to show that you are actually doing what you say you are doing.  Internal audits are emphasized with honest findings, and corrective actions.  

The ISO updates in 2000 turned focus to “continual improvement” and “customer satisfaction”.  Continual improvement projects must be identified, and customer satisfaction must be measured.   The ISO9001:2008 version went into greater depth of all prior versions, emphasizing processes, process owners, measurable goals and how they impact continual improvement and total customer satisfaction.  

With the most recent updates of ISO9001:2015, there is even greater emphasis on business management and leadership, and top-down management involvement.  Each employee should be aware of the organization’s mission statement, quality policy, and what their role is in achieving these goals.  Top management should be involved with communicating the quality management system, and the importance of each employee’s role to the organization.

ISO9001:2015 puts more emphasis on risk based thinking, and having contingency plans in place.  The bottom line is that businesses that adhere to an ISO compliant quality system are poised for the future, with quality systems in place that focus on total customer satisfaction.

Total customer satisfaction reaps many benefits in customer retention, increased volume of business, and new business referrals.  The efficiencies recognized when implementing ISO leads to cost-efficient improvements, thus saving time and money.  

Michiana Global Mold is a superior plastic injection mold designer registered to ISO9001:2015 in the United States, and ISO9001:2008 in China.  We offer offshore mold making options, rebate programs and high-volume discounts.  Contact us today for a FREE injection mold design consultation.  

Advantages of an ISO Registered Mold Making Shop

There are many advantages gained with using an ISO Registered mold making facility for construction of your injection molds.  Plastic injection mold making shops are expected to meet just in time delivery deadlines with tight tolerances within specifications.  Today’s injection mold making industry leaves no room for error as mold making shops must utilize modern technology with experience and in-depth knowledge of the injection mold making process in order to satisfy the stringent requirements of OEMs today.

The Internationally recognized quality standards of ISO9001, ISO/TS16949 and AS9100 set common parameters for various industries around the globe to measure their performance in either their service or product with a uniform set of standards.  Any supplier to the Automotive industry should be registered to ISO standards. In some cases, proving compliance may be adequate for a 3rd tier supplier, although most 1st and 2nd tier suppliers must be registered to either ISO or ISO/TS.

This gives Automotive suppliers around the globe the same set of standards to adhere to, making the job of the Automotive Quality Engineer from one of the top Automakers a little easier to compare vendors.  In order to stay in the preferred vendor status, an injection molding shop and even the injection mold making shops must not only be registered to ISO standards, they had better be practicing their Quality Policy and performing continual improvement projects in order to stay competitive.  

Mold making facilities meticulously follow detailed checklists ensuring that all issues are recognized and address prior to cutting steel.  ISO Registered mold making shops that follow Advanced Product Quality Planning (APQP) reveal any critical issues with mold construction such as critical fill areas to tight geometric areas, the need for CAM action, lifters or specialty ejection systems.  Identifying these critical issues ahead of time is crucial to fulfilling a tight deadline with a quality mold.  

Michiana Global Mold is a global supplier of high quality injection molds, registered to ISO  9001:2015 and implementing our Quality Policy throughout the organization.  We have been satisfying the stringent requirements of the Automotive industry with high-quality, custom, precision injection molds for over 52 years.  Contact us today to see how we can assist you with your injection mold building needs.

Mold Design and Automated Injection Molding

When an injection mold designer begins a development of the mold design, they must be aware of the environment in which the mold will run.  This includes the size and type of press the mold will run in, the material used for molding, and any auxiliary equipment used for automation as the location of tie bars and cooling lines must not interfere with setting and running the mold.

 

Vacuum Conveying System

 

A vacuum conveying system is an automated way to get the material into the press, with the right suction and force.  Vacuum conveying systems suck the material while still in pellet from the gaylord or drum into the hopper of the press, providing a steady flow of material for continuous production.   Vacuum conveying systems pull in a steady flow of material, and control the amount of material in flow to the press, and are also helpful with controlling the moisture content in the material.  

 

Sprue Pickers Aid Automation

 

Sprue pickers are robotic arms that reach into the press and grab the runner when the mold ejects, instantly separating from it the parts which can then fall into a bucket or onto a conveyor belt.  Some robotic sprue pickers reach in and pick up the runner then drop it either into a separate bin, or directly into a grinder where it can be ground up and reused as regrind material.  

 

Process Monitoring

 

Injection molders use process monitoring systems to constantly monitor the press settings such as temperature and pressure, alerting an operator if the job begins to run out of specification.  Some monitoring systems also provide material resource planning functions, tracking job due dates and material inventory for scheduling of jobs.  

 

All of the additional auxiliary equipment must function properly and work in conjunction with the mold when it opens and closes and operates on the tie bar.

 

Michiana Global Mold has vast experience designing and manufacturing molds adhering to customer specifications and each unique environment.  Contact us today for a FREE design consultation and to learn how we can assist.  

Mold Design Considerations for Thermoplastic Resins

The most common type of polymer used in injection molding is thermoplastic resins.  There are many different types of resins with various properties to meet part specifications for functionality.  When designing injection molds, the engineer must take into consideration all properties of the resin specified for the produce including adhesion, elasticity, resistance to high temperatures, shrink rate, resistance to corrosives, and desired finish whether matte or polished.

 

The cooling and shrink rate are of the utmost importance, as some parts with a high shrink rate will need the cavity designed accordingly so the finished product will cool and shrink within specifications.  Cooling rate is also important for ejection, as the resin must completely solidify prior to mold ejection.

When an injection molded part has a critical functionality, mold flow analysis may be helpful in determining resin flow into tight geometric areas.  Mold flow analysis clearly shows with computer aided simulation how the resin will flow as determined from its properties.  Predicting how thermoplastic resin will flow in the mold and cavities prior to cutting steel can be a valuable tool in avoiding costly mistakes.  Conducting the proper advanced quality planning with mold flow analysis can greatly improve lead times.  

Most journeyman mold makers will already possess the knowledge of hos particular resins flow just from experience.  A skilled design engineer with experience in manufacturing molds will have the knowledge to design the tool to produce a part to print specifications, with the chosen resin properties playing a huge role in tool design.

At Michiana Global Mold, we have been providing high quality precision molds for over 60 years, possessing more than 500 years of combined experience.  Our staff of highly skilled design engineers and journeymen mold makers are the best in the business with vast experience in various thermoplastic resins.

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

Expert Brass Forging Die Manufacturer

 

Copper and brass forgings provide high density parts with very accurate dimensions, achieving a high level of consistency.  Brass forgings are used in several commercial and industrial applications such as automotive, aerospace, marine, transportation, plumbing, lawn and garden, heating and cooling and even the medical industry.  Brass forgings are also used to provide durable strength in architectural applications.  

Due to the precision required of brass forgings used in critical applications, you need a brass forging die maker with expertise in tool making skills.  Michiana Global Mold is a full-service tool and machine shop with vast expertise in manufacturing various molds and tooling, made with top quality components and precision accuracy.  

We have a large capacity modern tool making facility located in the heart of the Midwest in Mishawaka, IN, where we have been supplying quality molds and tooling for over 50 years!  We specialize in complex, precision tooling and brass forging dies, manufactured to your specification within +/- .001”, and on time.  

Michiana Global tackles the complex designs and intricate tooling that others shy away from.  With confidence and experience, we can manufacture your brass forging dies within your tight tolerances, and deliver high volume projects on time.  We manufacture forging dies with a heat treated and polished finish, for single or mass produced production requirements.

With a full-service tool shop, we also do engineering changes if necessary, saving you time and money.  We utilize a full line of CNC machines manufacturing brass forging dies with cost effective, efficient solutions, giving you the best value.   

Our expert design an engineering team can provide a free design consultation or provide reverse engineering services with our experience and CAD/CAM software and equipment.   We adhere all processes to our strict quality policy as an ISO registered mold and machine shop.  

Established since 1964, Michiana Global Mold has over 50 years of experience providing custom, precision injection molds, tooling and forging dies.  Contact us today for a free design consultation and to see how we can save you money on your procurement of brass forging dies.