Tag Archives: plastic injection mold manufacturers

Design Plastic Injection Molds to Press Specifications

A plastic injection mold designer must consider many factors when designing injection molds, including the press the mold will run in.  Knowing the press specifications is very important in order for the mold to operate properly, and most efficiently during injection molding production.  

Vertical Press Clamping System

The orientation of the clamping system is of course a very important consideration, as this determines whether the mold will open horizontally or vertically.  A vertical molding press is used in over-molding production, also called insert molding because the molten plastic is molded around an object.  An example would be an electrical wiring harness with plastic molded around a portion of it, clamps or even something like knives where the handle is molded around the metal.  

The insert in a vertical molding press can be either steel or even plastic.  A vertical press requires molds for the top and bottom, as a vertical molding press has a rotary table which holds at least two bottom (B) sides of the mold, while the top half (A) half comes down to close on the bottom half molding the part.  

There is usually one top half, and at least two or more bottom sides to the mold, so that when the A side is molding the part on the back of the table, another B side is in front of an operator or a robot loading an insert into the open mold.  Once molded, a robot or operator can unload the over-molded part from the mold, prior to loading new inserts into it.   Constructing molds for a vertical molding press is quite different than for a horizontal molding press, even though the concept is the same.  

Horizontal Molding Press

The most common type of injection molding operation is in a horizontal press, requiring an A side and B side, closing together on a horizontal plane to mold the parts.  When the horizontal mold opens for ejection, parts usually fall into a bin below or are grabbed by a robot and taken to an inspection area.  Most horizontal molding operations do not require an operator at the press, as the vertical over-molding jobs do without automated equipment.   

Horizontal molding presses are very efficient and non-labor intensive, with a top-quality high-performing injection mold, a horizontal molding operation can run for hours in a lights out environment.  

Regardless of whether the mold is for a vertical or horizontal press, the placement of water fittings and hoses is of the utmost importance in designing the tool.  The clamping pressure and press tonnage are also very relevant specifications, in order for the mold designer to calculate the pressure of the molding operation while also considering the material chosen and how it will flow into critical areas.  

Michiana Global Mold has decades of experience designing tools for various plastic injection molding environments, meeting tight tolerances with high performing, precision custom injection molds.  Download a FREE copy of our book “Design Considerations for Different Molds” for more information.

Michiana Global Mold has decades of experience designing and building precision custom injection molds for various industries. Contact us today to speak with one of our knowledgeable engineers for a FREE design consultation on your mold building requirements.  We can custom design molds for your applications, regardless of your molding environment.

Advertisements

Benefits of an ISO Registered Mold Shop

 

There are several benefits to having an ISO Registered mold shop for construction of plastic injection molds.  Injection mold suppliers today are expected to meet tight tolerances, and even tighter deadlines.  With just-in-time delivery, this leaves no room for error.  

Plastic injection mold suppliers must follow a detailed checklist to ensure that all issues are addressed ahead of time, prior to cutting steel.  When Advanced Product Quality Planning (APQP) is performed, critical issues are brought to light prior to mold construction, thus ensuring a quality job the first time.

In addition to APQP, ISO Registered injection mold suppliers must consider all inputs into their process, and evaluate their effectiveness of reaching the process goals.  All goals should have quantifiable measurable data, and those goals must be audited internally and externally.  

Any deviations from the course of satisfactorily attaining your goals are required to be explored with corrective actions, or an 8D response.  These requirements ensure that all processes are meticulously followed, resulting in a consistent process, which is required for consistent quality product.  

Many injection molders are required to be registered to ISO standards, especially when supplying industries that require a high level of consistent quality product output.  When injection molders supply the automotive industry with precision components, they must rely on a top-notch, quality driven mold construction shop.  

This is where an ISO Registered mold maker will add value to your supply chain as already having went through the rigid requirements of documenting and auditing their processes.  An ISO Registered mold maker will know exactly what is required in order to satisfy the rigid requirements of top of the tier automotive suppliers such as Ford, GM, Toyota and Honda. To learn more about the Benefits of an ISO Registered mold making shop see our recent Blog on the Benefits of ISO Registration.

When adding an ISO Registered mold maker to your supply chain you are bringing value beyond their ISO certification.  In ISO Registered mold maker is already following detailed checklists, and ensuring quality procedures are in place.  When you need documentation for your customers ensuring the level of quality of your product, and your processes, adding an ISO registered mold maker brings the most value.  

 

Michiana  Global  Mold  is  Registered  to  ISO  9001:2015,  implementing  our  Quality  Policy throughout  the  organization  with  top  down  management  involvement.   We  are a top-quality,  custom  precision  injection  mold company serving various industries  for  over  52  years.   Contact  us  today  to  see how we can assist you with your injection mold building needs.

Top 5 Benefits of ISO Certification

complex20320plate20mold-min

An Overview of the Benefits of ISO9001

 There are many benefits of ISO certification, a globally recognized and accepted set of quality standards applicable to companies in various industries.   Conforming to ISO9001:2015 provides many benefits to manufacturers in all industries including plastic and steel production for automotive, consumer electronics and military and defense.

Businesses that provide design work such as injection mold makers have additional standards and responsibility to their customers, and the supply chain to which they contribute.  Producing quality product, on time, and within customer specifications is key to providing exemplary customer service.   ISO standards prompt companies to detail and audit all systems in their business, implementing corrective actions when those processes are not meeting their goals, applied to all processes, not just manufacturing.

Conforming to ISO standards also means that you have a written plan, detailing needed resources and expected goals for all business processes including business strategy and planning, sales and marketing, production, quality, and customer service.  ISO 9001:2015 puts added emphasis on risk management and leadership engagement, all necessary components of successful, globally competitive businesses.

Here are the Top 5 Benefits of ISO Certification

  1. All Processes are Identified, and Audited for Effectiveness

Processes includes the required resources needed to attain a specified goal.  Each process has an owner, a person responsible for successfully attaining specified goals.   The process owner determines the best way to measure the effectiveness of a process, and implements corrective actions when necessary.

  1. Contributes to Goal-Oriented Teamwork

Process owners must utilize human capital as a resource, creating one goal-oriented team.  Each team member should be aware of the company’s quality policy, and know how their role in the organization contributes to the overall business goals.

  1. Improved Efficiency Produces Improved Profits

Improving efficiency always equates to an improved bottom line.  Time is money, and continual improvement projects like Value Stream Mapping can improve efficiencies and profits for any business process.

  1. Utilizes Plan-Do-Check-Act (PDCA) business improvement process.  
  • Plan – Establish your objectives and a plan to achieve them
  • Do – Execute your plan with a structured framework
  • Check – Audit results against your objectives
  • Act – Make corrections and improvements.

The PDCA system Can be applied to any process and is utilized throughout the entire ISO process.

  1. ISO Certification Focuses on One End Result – Total Customer Satisfaction

Conformance to each and every standard ultimately leads back to total customer satisfaction.  Why does a business do what they do?  Customer Satisfaction is required for any business to survive, let alone thrive and grow.  With focus always on customer satisfaction, one of the major benefits of ISO Certification is that the business has the framework to keep current customers delighted and grow with referrals by providing continued exceptional customer service.

Michiana Global Mold is Registered to ISO 9001:2015, implementing our Quality Policy throughout the organization with top down management involvement.  We have been top-quality, custom precision injection mold makers for over 52 years.  Contact us today to see how we can assist you with your injection mold building needs.  

 

Resin Injection Molding

3D printing

Molding With Plastic Resin

Resin injection molding is the manufacturing process of molding raw plastic pellet into usable parts.   Thermoplastic resin is the most common type of plastic used in the polymer molding process.  The resin, or plastic pellets, is used by injection molders to make parts for a wide variety of industries.

 

Custom injection molding is the process used by custom molders to make parts that are designed by others, typically engineers in the Automotive, Aerospace, Consumer Electronics, or Medical field.  Injection molding is also used for the Furniture, Construction, and Toy industries, although precision molding is required for the former mentioned industries requiring a high level of quality with tight tolerances.

 

Each resin has a melt temperature when it becomes pliable, which allows it to flow through an injection molding press, into a barrel and screw, where it is injected with pressure into a steel mold forming the desired parts.  After forming, the mold ejects the parts and closes again to prepare for another cycle.

 

Characteristics of Thermoplastic Resins

 

Thermoplastic resins have a unique ability to be strong and durable, yet also lightweight which makes is a desirable material for several functional parts. They can be reinforced with glass filled polymers, or they can have a rubber like appearance, and several variations in between.  They can be made into virtually any color, size or shape.  This flexibility is the main reason that plastic resins are the material of choice for supplying various industries with necessary functional parts.  Some examples:

 

  • Polycarbonate
  • Polyethylene (low or high density)
  • Polyethylene Terephthalate (PET)
  • Polypropylene (Acetal)
  • Polyphenylene Ether (PPE)

 

The experienced molder has all procedures in place to provide full traceability throughout the resin injection molding process up to and including shipment of quality parts that meet or exceed customer specifications, along with proper documentation.  Contact Michiana Global Mold today to see how we can help you with your injection molding needs.

 

 

Injection Mold Types: Production Molds

 

As their name suggests, production molds are used in the final stages by the injection mold makers. Unlike prototype molds, production molds are meant to be used repeatedly for long periods of time, so they must be durable and able to handle harsher conditions. Since it is the final stage of the process, the end product is meant to meet all of the project requirements and specifications.

Custom mold makers will skip the prototype mold if customers request that a project only goes through to production instead of working with a prototype. While the prototype can save money, it can also require more time as the production of the first few parts is meant to be a test run. Custom injection molds that go straight into production molds are given a much longer duration for the design process to ensure the first product is nearly perfect.

Production molds are not meant to be modified or changed. If the first product is too far off of the necessary requirements, you may need to start from the beginning. However, without the additional time for modifications, these injection molds can actually save time as long as the design process goes smoothly.

If you want to avoid using prototype molds, you need to find expert injection mold makers. New companies do not have the knowledge or experience required to create a final product that is nearly perfect on the first round. A number of things can go wrong and many considerations can be missed in the design stages. These are problems that expert injection mold makers have already encountered and learned to fix before moving to the production mold. In the event that there is a problem with the production mold, the experts can make modifications to avoid starting over again.

Injection Mold Types: Insert Molds

 

Insert molds are one of the more difficult types of injection mold types. Injection mold makers have to consider several different areas to complete the final mold. Insert molds can combine plastics and metals (and some other types of materials) so that the final part can connect to different parts of the final product. Custom mold makers typically have to ensure the insert mold is wear resistant, has a reduced weight, conductivity, and tensile strength.

Insert mold makers must create parts that can be molded into other plastic components. There are a wide range of applications for insert molds, such as screws, studs, pins, rivets, tubes, bushings, and surface mount pads. The custom injection molds have to be able to create parts that are more durable and sturdy than other molds because they will be used with metal, which can be very harsh on plastics.

The purpose of insert molds is to reinforce the final product. They reduce the amount of time required to assemble parts, the cost of labor, and improve the strength of the final product. As they are meant to be made of durable plastics, they also help to reduce the weight of the part.

This particular mold type follows the same process as other injection molds. The primary differences are the design and QA processes. The design has to meet strict requirements to ensure the insert will be able to function as intended. The following are the two most common considerations during the design process:

  • Determine the means for holding the insert during the custom injection mold process
  • Any required undercuts or bosses required to strengthen the final product

Insert molds also tend to have a more rigorous QA process to ensure the final part provides the necessary durability and strength.

 

Custom Injection Molds

 

Custom injection molds provide manufacturers with a way to utilize one of the quickest processes to mass produce a product. While most plastic injection molds are customized, it is possible to use existing designs to quickly create molds that are basically recycled instead of customized.

The reason that most plastic molds are customized is because of the requirements and standards that every part and product must meet. If you already have a mold for a 1.25” screw, but you need one that fits a 1” screw, you have to create a new mold to produce the different size. Seldom can a manufacturer work with existing mold designs without having a custom injection mold made to complete the project.

Custom plastic molds offer more than just a way to meet specifications though. If you aren’t sure what method of assembly a product will be best for, or if a tolerance can be met with a particular type of rib, a custom injection mold can be a way of testing different designs to see which product is best for the intended purposes.

Custom injection molds can also be used to test out different plastics to see which ones work best under various conditions. For example, if you have been working with a metal mold that now needs to be replaced, a custom injection mold can be made to see if a plastic mold will be able to tolerate the harsh conditions that the metal mold had undergone. If the custom injection mold can handle the temperatures and other harsh conditions, you can save a considerable amount of money by making the change.

Custom injection molds are sometimes compared to 3D printing as well. There are times when 3D is more cost effective, but on the whole, plastic molds tend to be better for longer term projects as the process tends to be much faster and the final product more durable. Custom plastic molds can typically produce much larger parts than 3D printing.

Experienced custom injection mold makers can help you determine what mold type is best for your current project by reviewing your specifications and the final requirements for the finished product.