In order to produce save costs and time in the process of plastic injection molding and improve production efficiency of injection mold, mold manufacturers increasing use of new materials and new technologies, and these new materials and new technologies in a certain extent, represent plastic injection mold manufacturing a new trend.
New material to promote the development of mold inserts
There is a new material can reduce the mold manufacturer’s investment cost and time. The new cobalt-chromium alloy, called MP1, specifically for the Rapid Prototyping (RP) device, a direct metal laser sintering (DMLS) process was developed. The material from the German rapid prototyping equipment and materials suppliers EOS (ElectroOpticalSystems) GmbH company. Now users in North America and the United States through the EOS of North America MorrisTechnologies companies to buy such material.
MorrisTechnologies is an injection mold development company, this company the first time, the materials used in commercial manufacturing. In the company’s use of the process, the cobalt-chromium alloy has been shown to have high strength, high temperature performance and corrosion resistance. MorrisTechnologies was the U.S. introduction of the first EOS’s EosintM-level rapid prototyping machine company, because at that time the company had foreseen DMLS-based rapid prototyping huge market. However, experiments found that when the market still do not have a lot of material to meet their customer’s application requirements.
“There are many projects require rapid prototyping solutions, but the experimental conditions, our customers need for materials with better high temperature and corrosion resistance and higher mechanical properties.” MorrisTechnologies the company’s president GregMorris said, “even if it took more time and money, stainless steel or other alloys still can not meet their requirements. ”
In order to address these issues, MorrisTechnologies has selected EOS of cobalt-chromium MP1 material. Morris said that the alloy Rockwell hardness of 30 to 40 between the mold to produce a small complex products, these products are now typically used or EDM machining method to create.
Because the structure of this material layer is very thin, only 20μm, so products can be fully sintered. Morris believed that such materials and metal laser sintering technology to help direct Injection Mold Making manufacturer industry in order to lower the cost of production of fine-type core and cavity inserts. “At present, there is no reason why a lot of mold manufacturers to adopt the technology, in my opinion, is because many people believe that they only used the old order manufacturing mold core and cavity be considered the best.” Morris explained.
Mold maker Linear Mold & Engineering Inc. CEO JohnTenbusch not hesitate to adopt the above techniques. Because Tenbusch found that the company’s EOS direct metal laser sintering rapid prototyping equipment, new customers have even extended to Mexico and South America.
In the injection mold manufacturing process, using a typical EDM equipment (EDM) is a more popular on welding, and wire cutting in the fast-forming mold is also a gradual increase in the use. This, Tenbusch explained: “With wire cutting can help us save time, that is, we use wire cutting to cut out the cavity, while the insert such as the fine components using DMLS process to process.”
Tenbusch introduced a high accuracy of this method, but do not need to be a lot of measuring points, while rib muscle can be separated and as vents. Can also be processed using the wire cutting some stainless steel inserts, and place them in the mold. If the material hard enough and long enough life time, processing personnel will not have the details necessary to EDM parts, and as for the usual pre-hardened high-tensile steel nitrided die is the case. The use of wire cutting can be 4 to 5 weeks to complete mold manufacturing, which accelerated the root cause lies in the DMLS equipment EOS EDM equipment replaced.
Co-Cr-MP1 is the EOS family of the company’s new stainless steel 17-4 in a series, it is planned to the market this year is MaragingSteelMS1, this is a 18 martensitic steel 300 (Model: 1.2709), its performance at least equivalent to or even superior to the traditional mold steel, very suitable for fabrication using DMLS mold insert.
Less polished, multi-coated
U.S. Bales Mold Service, Inc. is a leading injection mold to provide polishing and electroplating services. Out of consideration for the customer to reduce costs, the company is now seldom used premium EDM polishing technology, replaced by the introduction of plating technology in the mold surface coatings. Bales Mold Service Company President SteveBales, said: “Now is not required each mold polishing, and coating use is gradually growing. We have adopted in lieu of electroplating polishing EDM live, you can save time and money for customers.”
As we all know, fillers will shorten the life of injection mold. With the injection molding of the growing amount of filler, filler to the mold caused by corrosion and wear to highlight the growing problem. The increase in coating for mold, such as Nicklon (a nickel-PTFE coating) and Nibore (nickel-boron nitride) is able to play a very good protection. At the same time with the plastic lubricant additive expensive compared to those of coating and very cheap.
Ritemp be provided with suitable temperature with
Australia Ritemp Corporation (Australia processing and auxiliary equipment suppliers ComtecIPE branch) in 2005 launched the Ritemp mold cooling technology. At present the technology in North America, from SWM & Associates Inc. exclusive agent.
Using Ritemp mold cooling technology, can achieve higher cooling efficiency and shorter cycle times. Such as injection molding an electrical 15g shell, use the GEPlastics the NorylPA / PPE, for the two-cavity mold, molding cycle 18s. The use of Ritemp cooling technology you can use the four-cavity mold, and make molding cycle down to 13s, the resulting output can be more than 7 million. SWM & Associates Company believes that if the downstream equipment can handle more products, molding cycle can even be reduced to 10s.
Ritemp works as follows: Ritemp with the mold surface of the cooling water tank instead of water cannon. The vacuum created by removal of air and water to boiling temperature in the cooling room. Water evaporation to the mold surface heat exchange, and then discharged through the sink. In the evaporation process, the water molecules absorb heat and, through the mold temperature control system for regulating the heat level, thereby ensuring that the mold temperature.
The use of submerged gate gate insert to eliminate the visible signs of
This submerged gate inserts from Germany, i-mold company, its injection site was designed in the end products, while the flow channel from the front open, so that the surface of positioning products on the gate inconspicuous place. For example, in product outer edge of the side gate at the bottom of rib muscle, people can not see the obvious signs of the gate.