the number of molding cycles is less than 500 repetitions, used for a low-volume production such as prototypes. Mold material requirements are low and at low cost. Die casting materials are permissible. Epoxy resin or it’s alike are frequently used plastic part materials
Although mold class is a good basis for designing tooling longevity, there is no method to determine exactly how many cycles a mold will last. However, the factors below each impact the life span of a mold and the life can be maximized for molds that are well cared for.
Materials – the life span of an injection mold is significantly impacted by the material of the injection molded products as well as the material of the tooling itself. Molds made of a softer metal, like aluminum, do not generally last as long as harder metal molds such as stainless steel. As for the silicone blend being molded, some formulations contain abrasive or corrosive ingredients, which can wear down the tooling and decrease the life span.
Conditions – injection molding manufacturing occurs under a range of operating conditions and some environments are tougher on equipment than others. Additionally, cleanliness and the likelihood for contaminants such as moisture, dust, and debris also impact the life cycle of tooling.
Length of Cycles – As a rule of thumb, injection molds tend to last longer when they operate under longer cycle times compared to high-speed production cycles.
Proper Maintenance – this is one of the key elements that impact tooling life span yet it is often overlooked. Preventative maintenance and the associated inspections are vital to maximizing the life of injection molds.
The number of injection molded parts determines the cost of injection molding
a critical element when determining maximum cycle counts is knowing part defect frequencies and locations that can be affected by many of the above criteria. Part defects “localized” by unbalanced filling or steel variations must be recognized and considered when setting maximum cycle counts. But generally speaking, anytime you over-run a mold, you increase the risk of molding bad parts through burns, shorts, weld lines, or dirty or flashed parts. Mold off-gassing or residue will end up someplace if it can’t escape through clean vents.