Injection Mold
Injection Mold Manufacturing and Design Guide
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What is plastic molding?
The basic principle of resin molding is that resin (plastic) is heated and melted, then cooled and hardened into a predetermined shape using a mold or other means, and then removed.
Depending on the application and shape, various resin molding materials are molded in a suitable manner, taking advantage of their characteristics.
Generally, "thermoplastic resin" uses pellets of resin (plastic) in the form of rice grains, while "thermosetting resin" uses powdered resin. Pellets or powders may also be used, which have undergone a process called "compounding," in which additives and coloring agents that improve their functions are mixed into the resin.
For stable resin molding, it is important to control molding conditions such as temperature, pressure, amount of resin material, and injection speed. In each process, attention must also be paid to the adhesion of foreign matter such as dust and dirt (e.g., electrostatic adhesion), which can cause defects.
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GRT offers complete injection mold making services as well. GRT can turn around your urgent needs quickly and get it to market fast with our experienced molds makers meeting all of the custom specifications you need using such applications like Mold Technology, VDI Stardand ,JIS Stardand,BSI Stardand or High Polish SPI type requirements.
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What are Plastic Mold Steels?
Plastic mold steels, also called mold steels or tool steels, are a type of steel alloy made for use in making plastic injection molds. These steels are designed to handle the high temperatures, pressures, and corrosive conditions that come with the plastic injection molding process.
What are the Primary Characteristics of Plastic Mould Steels?
High hardness:
To resist wear and tear, and maintain the mold's shape and surface finish.
High thermal conductivity:
To efficiently dissipate heat generated during the molding process, reducing the risk of thermal shock and warping.
High corrosion resistance:
To resist the corrosive effects of plastics, mold release agents, and cleaning chemicals.
Low thermal expansion:
To minimize warping and distortion of the mold due to temperature changes.
What Type of Steel is Used for Molds?
When it comes to injection mold materials that don’t have any abrasives like glass fibers or corrosive ingredients, P-20 Steel is the most popular mold steel for plastic injection mold, because it has good wear resistance and it’s reasonably priced.
There are some common plastic mold steels used in the plastics industry. They all have different properties and uses.
Here are some of the most common ones:
These are only a few examples of the many plastic mold steels available. The choice of steel alloy often depends on the specific application, the type of plastic being molded, and the desired properties of the mold.
Which Tool Steel is Right for a Plastic Injection Mold?
Deciding which tool steel to use for a plastic injection mold depends on several factors, including: the kind of plastic being used, the mold design, the expected volume of production, the desired properties of the final product.
The Society of the Plastics Industry (SPI) classifies mold tooling into five different groups, ranging from Class 101 to Class 105. Each class has its own specifications and requirements and is generally determined by the volume of production.
Here's a breakdown of each class
Class 101: This is the biggest category. It’s often used for massive production runs. The molds are built to endure big volumes and are commonly used in mass production.1 million or more.
Class 102: This is for medium to big production runs. It’s built to be tougher and resist corrosion, so it can handle runs that are not as big as Class 101.Not exceeding 1 million.
Class 103: This is for medium production runs. It’s built to be more accurate, so it can handle runs that require really good parts.Not exceeding 500,000.
Class 104: This is for low to mid-sized production runs. It’s built to be versatile, so it can handle runs that require options and alternatives.Not exceeding 100,000.
Class 105: This is for lowest production runs. It’s built to be option-friendly, so it can handle small runs or making models.Not exceeding 500.
Note that the SPI system isn’t a firm classification, and some molds might cross over between categories. Also, which mold you pick relies on what you need, like what kind of plastic you want to make, what your mold design is, and how many you expect to make.
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How to Get an Accurate Injection Mold Quote?
Step 1. Provide detailed specifications:
Tell the supplier what it looks like, how big it is, what it’s made of, and what it does.
Tell the suplier how many you want and when you need them. schedule.
Step 2. Clearly define the mold requirements:
What kind of mold do you want? Harden Steel, Mild steel?
What kind of finish do you want? Polished, brushed, anodized?
Are there any special things you want, like cooling channels or ejector pins?
Step 3. Provide accurate production volume and schedule:
Tell the manufacturer how much you plan to produce and when so they can estimate how long the mold will last and when it will need maintenance.
Step 4. Specify the desired mold design:
Tell me which design software you use or send the 3D file.
If there’s anything specific you want the supplier to keep in mind, like limited space or a certain material you need to use, let the supplier know.
Step 5. Provide accurate part dimensions and tolerances:
Give suppliers the part dimensions, including tolerances, so they can design the mold correctly.
Step 6. Request a detailed quote:
Ask the manufacturer to give you a detailed quote that includes:
How much it will cost to design and make the mold
How much it will cost to make the tooling (things like mold inserts, ejector pins, and cooling channels)
How much it will cost to make the parts (things like labor, materials, and overhead)
Any other costs (like maintenance, repair, or replacement)
Step 7. Check the quote:
Look over the quote carefully to make sure it has everything you need and costs what you expect.
Ask questions if you don’t understand something in the quote.
Step 8. Ask for a sample or prototype:
Ask the manufacturer to give you a sample or prototype to make sure the mold is designed right and the product is what you want.
Step 9. Negotiate the terms:
Go over the quote and discuss the terms, if needed, to make sure we’re on the same page.
Step 10. Check out the manufacturer:
Look into the manufacturer’s reputation and experience in making molds for similar products.
Make sure they have experience with similar materials, production quantities, and design specifications.
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How to choose the right mold supplier in China?
In China's economy belongs to the ladder-type distribution, so you will find that the quotation offer is also a ladder-type distribution, which the material costs and equipment maintenance costs are almost the same, but the cost of labor, quality management, management costs and plant rentals make the quotation still have a gap.
The role of GRT is to help you find a balance between the price gap and the quality gap.
Although foreign media publicize that China is no longer in the era of low-end industrial chain relying on simple OEM processing, in fact, China does have significant development in high-end industries. That said, you can still find value in China.
What is the Injection Mold-Making Process?
The whole injection mold making process includes everything from design and prototyping to finishing the mold and getting it ready to hand over to the production department or package and ship to the customer.
In the specific production process, we will use the Mold Process Production Schedule to control the time progress of each step.
Making an injection mold is a complex process that involves several steps to create a mold that can produce high-quality plastic parts. Here’s an overview of the process:
1.Design and Prototyping:
Create a 3D design of the mold and part using UG or PROE software.
Create a prototype of the part to test its functionality and make any necessary design changes.
3.Material Selection:
Pick the right stuff to make the mold out of, like harded steel, mild steel, based on what the part needs and how many you’re making.
Think about things like how long it’ll last, if it’ll rust, and how well it’ll move heat.
2.Mold Design:
Create a detailed design of the mold’s internal features, such as cavities, cores, and ejector pins.
Ensure the design meets the required tolerances and specifications.
4.Machining:
Cut and machine the mold material using CNC machining, EDM, or other precision machining techniques.
Create the mold’s internal features, such as cavities, cores, and ejector pins.
5.Assembly and Installation:
Put the mold together, including the mold inserts, cores, and ejector pins.
Put the mold inserts and cores in the mold, making sure they fit right and don’t hit anything.
6.Inspection and Testing:
Look at the mold to make sure it’s not messed up and meets our quality standards.
Try the mold out to make sure it works, including the ejection system, cooling system, and part quality.
7.Quality Control:
Do a bunch of tests to make sure the mold is just right and meets all the specs.
Check how the mold works, including part quality, dimensions, and how it looks.
8.Packaging and Shipping:
Wrap the mold up nice and tight so it doesn’t get hurt on the way.
Send the mold to the customer or wherever it’s going.
Other things that might be done during the process include:
Surface treatment: Put a surface treatment on the mold, like chrome plating or nitriding, to make it tougher and more resistant to rust.
Coating: Put a coating on the mold, like a release agent or lubricant, to make it easier to get the parts out and to reduce wear.
Mold maintenance: Give the customer instructions on how to take care of the mold so it keeps working well and lasts a long time.
How do we do the quality control of the mold?
The first method is that we manage the quality of the molds on site according to the quality control needs of different customers and according to their control standards. For example, according to the standard of company A to manage. The advantage of this method is that it is 100% the control demand that the customer wants.
The second method is to manage the quality control according to the quality control of GRT supplier, although this also ensures the quality of the mold to a great extent, but the management method is different and may be a little different.
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