Almost all people know the importance of the mold, but many people do not know how the mold is made, now I share with you some:
Manufacturability and Feasibility
In this initial stage, design engineers, tooling engineers, materials engineers, manufacturing engineers, quality engineers, and lab technicians work together to determine product specifications, mold component functionality, mold materials, operational constraints, and any needed product enhancements and improvements. The team especially looks for any potential problems in part geometry or tolerance that might result in poor steel conditions or require special tooling features such as lifters, slides, and threading/unthreading. The physical and chemical properties of the selected resin are also evaluated so that the proper mold steel can be selected and mold cooling be reviewed. Mold flow evaluation is also undertaken to determine the best type of gate and gate locations, in addition to determining proper vent locations.
Manufacturability review includes confirmation of standard plastic design practices and incorporation of mold details to create the most robust design possible. Tooling specifications and mold sources are finalized and purchased component sources qualified. A comprehensive process failure mode effects analysis (PFMEA) is also completed.
Preliminary 2D and 3D design models are constructed to determine mold sides and steel sizes. Once these are reviewed and approved, the detailed design is finalized.
Final Design Specifications
The mold builder is given the tool design specifications for mold construction. Final adjustments and modifications are done in-house, with special attention given to manufacturability and critical dimensional requirements.
Construction of Primary and Secondary Tools
Detailed mold drawings are completed and construction standards are reviewed and verified. The mold builder’s progress is closely monitored and on-site meetings are held. The completed mold is inspected against a comprehensive checklist.
Bring the Mold In-House for the Initial Sample
A molding process is established that is acceptable to the manufacturing department. Processing parameters are recommended and established. Initial sampling using scientific molding practices is carried out; cavity pressure transducers in the mold accurately determine the filling profile over time. Sample parts are qualified.
Make Any Final Mold Corrections
Any needed process adjustments are made as required. Mold construction is verified and the process is detailed and documented so it can be used in the future with minimal setup time. Perfect parts are resampled and submitted to the customer. After final approval is obtained from the customer, the production process is launched.