Injection molding is one of the most common methods used in manufacturing plastic components. It allows for the production of intricate and highly detailed parts at high volumes. However, like any other manufacturing process, it presents several challenges. Two of the most prevalent issues encountered are warping and shrinkage. These defects can affect the overall [...]
Injection molding optical parts demands strict control over surface quality and heat transfer. Residual stresses, birefringence and weld line notches can all compromise optical clarity. Also, increasing mold temperatures can improve surface replication, leading to longer cooling times and increased energy consumption. Nickel-plated coatings were selected to address these challenges due to their ability to [...]
Design for Manufacturing (DFM) is the process of designing parts, components or products for ease of manufacturing to make a better product at a lower cost. This is done by simplifying, optimizing and refining the product design. The acronym DFMA (Design for Manufacturing and Assembly) is sometimes used interchangeably with DFM. The five principles examined [...]
Are you tired of sacrificing quality for efficiency in your short run plastic injection molding processes? Well, it’s time to put an end to that. Maximizing efficiency and quality is not only attainable, but it’s imperative for the success and growth of your business. In this blog post, we’ll explore the strategies and techniques that [...]
There are times when seemingly minor issues can negatively affect mold cooling. Here are some causes of inadequate cooling that I have seen. Air Lock Air bubbles within cooling lines can restrict flow through the lines, which, in worst cases, can cause “waterfall flow,” resulting in “air-locked” cooling channels. Any high points in the cooling [...]
There is a growing demand for injection-molded micro parts, which is closely linked to the ongoing miniaturization of medical devices, electronic circuit boards, connectors, hearing aids, bio-absorbable implants and precision healthcare devices. The automated mass production of these high-cavitation, micro-molded plastic parts — often in the tens or hundreds of millions —leaves little room for [...]
For moldmakers, new product development (NPD) projects represent both exciting opportunities and potential pitfalls. These projects offer the chance to work on cutting-edge designs for globally recognized brands, but they also come with unique challenges that can strain customer relationships and project timelines. In the moldmaking world, NPD isn't limited to entirely new products. It [...]
From specialized cooling component materials and conformal cooling inserts to standard machining practices employing new mold components, mold cooling has evolved and increased in efficiency in recent years. Historically, mold cooling systems were designed to circulate water or other media through the base plates, but not necessarily within the cavities. Newer technology creates optimized circulation [...]
With the proportion of free-form surfaces increasing and the precision requirements for mold processing rising, manufacturing molds of high quality and securing the stability and quality during production has become vital. 3D scanning technologies are a game changer in these processes. Mold Design with 3D Scanning and Reverse Engineering Reverse engineering aims to reproduce an [...]
Automation is an essential part of machining and profitable manufacturing. Mold builders striving to compete at the Industry 4.0 level must focus on embedded sensors, software and other technologies to collect and analyze data to improve decision-making. These technological improvements lead to increased speed and efficiency, predictive maintenance and self-optimization of the manufacturing process. Moldmakers, [...]