So where are we today with the integration of copper alloys in mold building? There are still major opportunities and major contributions to be gained by companies that are willing to use these products.

One example is there must be greater importance placed on water flow rates and controlling, such in molds when using copper alloys. To maximize the benefits of copper alloys the design of water flow should be to maintain “turbulent flow” versus “laminar flow”.

Turbulent flow maximizes the heat removal process. This turbulent versus laminar flow was not a significant issue due to the low BTU removal rate of tool steel. This without a doubt seems to be something that has long been overlooked by many in the industry because of the attitude, “It’s just a water line.”

If you do not believe this statement, ask any moldmaker how close they hold water line diameters/depths and whether turbulent flow calculations are used in determining watering systems. It is doubtful that any of them will acknowledge the need, because you will get the answer “it is just a water line”. Well readers, it is not just a water line anymore.

Another example for improving mold performance with copper alloy is cited in the October 2007 issue of MoldMaking Technology that references using bronze or aluminum bronze for the base material in making ejector sleeves for molds. These components when made using bronze material far outlast any tool steel sleeve and the problems, downtime and maintenance that results because of the tool steel will be a thing of the past.

In the last 10 years, cycle times for successful molders have been cut nearly in half and there is still opportunity to run faster through the use of copper alloys. The technology of copper alloys as molding surfaces combined with controlled water flow and with all of the experience gained in the last 20 years will produce success in meeting the faster cycle requirements. If you are dealing with a material supplier that only “parrots” the history of their products in applications, you need to get hooked up with suppliers that can help with facts that lead to improvement in the designs that you have on the board today.

The question today is, “Is there still room to make improvements in mold designs and mold cycles? The answer is “Yes!” The opportunities are endless, and mold capabilities where the cool time is less than the mold fill time are possible.

Work with sources/suppliers that have a niche in their respective market, a true history of expertise in their discipline, willingness to openly provide improvements without reservation and a drive to maintain a successful business model in their own operations.
History has shown for most that cheap molds run and perform like cheap molds. For companies that are into buying cheap molds it may take some time for their true cost to surface.

This is due to the real cost of a cheap mold never being exposed through the ranks of a company because the expense to get it running (productionized) is part of some departmental budgeting process that is not part of the initial mold cost, is not clearly visible, or is masked by the personnel involved in the mold procurement process. Remember, success does not come without a price tag and equally important is having the right people and right suppliers involved.