Usually the designer begins with a preliminary part design, which means the work around the core and cavity could change. After the calculation of the optimal draft of the part, the position and direction of the cavity, slides and inserts have to be defined. The 3-D system supports the designer with the calculation of a parting line and the segmentation into slides and inserts based on the 3-D model of the part.

Moreover, the mold system provides functions for the checking, modifying and detailing of the part. Already in this early stage, drawings and bill of materials can be created automatically.

When choosing the standard mold, the designer can define any size, thickness and number of plates. For example, a mold with two splitting lines or special molds with two ejector systems – one in the moving side and one in the static side – can be created quickly and easily.

When positioning standard components such as ejectors or screws, not only is the geometry of the component itself created, but also the necessary holes. In the case of the ejector pins, the counter-bore, the through-hole and the fit in all of the plates and inserts are affected. The system automatically stores the relationship between the holes and the components. For example, when a screw is moved, the tap in one plate and the counter-sink and the through-hole in other plates are moved with it so there will not be an error in the position of functionally related holes in different plates or inserts.

The possibility to copy, mirror or rotate components or whole sub-assemblies is very important for the efficiency of a CAD system. For example, if you want to design a multi-cavity mold, only one core and cavity has to be designed. All of the others can be created automatically by copying. In a 3-D mold design system this means the whole insert with all of the components that will be copied are selected in one step and then arranged in an array, mirrored or rotated with copying. The system then automatically creates all of the new holes in the plates and all of the new components. The bill of materials then automatically contains the new number of components and the NC table with the new holes.

This not only is possible for fixed standards but also for user components. These are the company’s own specific components that are defined by the user and stored in a user standard library. These user components can then be handled with the same logic and functionality as the standard library.

All of these features are provided in a new special 3-D mold design system. The big advantages of this system are:

Access to three-dimensional standard libraries from certain companies.
Possibility to create user libraries.

Automatic creation of drawings and the bill of materials.
Interfaces like IGES, STEP, VDA, DXF and STL (SLA) guarantee optimal connection to other systems. There also are modules for two and a half-, three- and five-axis CNC-programming. Electrode manufacturing and the automation of all of the cycles for the plates guarantee economical advantages. Three-dimensional design systems are available today for all common Windows NT and Unix platforms.

The use of a special 3-D mold design system can shorten development cycles, improve mold quality, enhance teamwork and free the designer from tedious routine work. The economical success, however, is highly dependent upon the organization of the workflow. The development cycles can be shortened only when organizational and personnel measures are taken. The part design, mold design, electrode design and mold manufacturing departments have to consistently work together in a tight relationship.