Custom Mold Manufacturing
At Advanced Prototype Manufacturing, we specialize in creating custom and prototype molds for different thermoplastic applications. Furthermore, we help our clients determine the molding techniques that best serve their various applications and projects. Our streamlined production process ensures that each stage is tailored to meet the specific needs of our clients effectively.
Types of Molding Techniques
Injection Molding
Custom injection molding is a manufacturing process where parts are produced in larger volumes with a quick turnaround time. Here, molten materials are injected into the mold. The most common materials used in this molding technique are thermoplastics or thermosetting polymers.
Compression Molding
Two-part mold systems are used to create the finished product in compression molding. The molding material is preheated and placed in an open cavity heated with continuous pressure. After the molding material has been cured, it is removed and cooled off to complete the process.
RTV Molding
RTV or Room Temperature Vulcanization molding is another technique known as resin casting or silicone molding. Custom mold products are created to manufacture products for prototyping or short-run productions quickly. Silicone molds are compatible with concrete for creating detailed castings. Silicone molds typically have a higher tooling fee compared to hard plastic molds.
Rotational Molding
Also known as roto molding, this unique process is ideal for creating hollowed materials without the pressure involved. The custom molds for this manufacturing process are inexpensive since they don’t need to withstand high amounts of pressure.
Custom Mold Process
Design & Conceptualization
- Client Consultation: The process begins with discussions between the client and the mold manufacturer to understand the product's requirements, including dimensions, material, functionality, and any aesthetic preferences.
- 3D Modeling & CAD Design: Engineers create a detailed 3D model of the product using Computer-Aided Design (CAD) software. This model is used to design the mold, ensuring that it meets all specifications.
- Design Review: The CAD design is reviewed and approved by both the client and the engineering team. Adjustments are made based on feedback.
Material Selection
- Mold Material: The choice of mold material depends on the product material, production volume, and desired surface finish. Common mold materials include steel, aluminum, or epoxy resins.
- Product Material: The material for the final product is also selected at this stage. This could be plastic, metal, rubber, or any other material suitable for the intended application.
MOLD STRUCTURE:
The seven systems of injection mold: Gating system, guidance system, molding system, core pulling system, ejection system, cooling system, and venting system.
- Gating System:
Runner: Where the molten plastic flows through before reaching different cavities.
Sprue: Where the molten plastic flows through from the injection machine to the mold.
Gate: The last opening that allows the molten plastic to flow into the cavities.
Cold Slug Well: When the molten plastic flows in the sprue and runner, it will solidify due to heat transfer with the mold. The cold slug well is where the solidified material is stored before entering the cavities.
- Guidance System:
In-mold opening/closing process, mold displacement will occur due to manufacturing tolerances and installation tolerances. When the mold is closing, it is required that the mold can return to its original position. This is where guidance and location (i.e. mold guidance system) fit in.
- Molding System:
Molding System: A closed space that consists of the core, cavity, and inserts, etc.
- Ejection System:
The ejector of the injection machine applies force on the press plate of the mold, which drives the ejector pins, ejector blocks, and lifters, etc. to push the product away from the core or the cavity and thus enable smooth mold release.
- Cooling System:
The mold itself is a large cooling system. To achieve a better cooling effect, one or more groups of cooling channels will be designed for the mold. Usually, the distance between the cooling channel and the product is twice the diameter of the channel. The coolant is not necessarily cold water – it can be water at 100 degrees Celsius depending on the mold temperature and sometimes it can also be hot oil.
How to assemble a plastic injection mold?
MOLD STANARD:
Mold Steel: ASSAB(Sweden), DAIDO(Japan),FINKL(America),AUBERT & DUVAL(France), Thyssen(Germany), LKM (China)
Mold Base: EMP, DME, HASCO, FUTABA, LKM.
Hot Runner: MOULD MASTER, SYNVENTIVE, HASCO, DME, YUDO, INCOE
Standard Parts: DME, HASCO, LKM, HEB, STRACK, OPITZ
Texture: VDI 3400, Mold-tech, Yick Sang, Tanazawa, etc
Software: Pro/Engineer, Solidworks, AutoCAD, Moldflow, Unigraphics, CATIA, Mastercam
M OLD MAKING IN-HOUSE:
Our Mold shop is well equipped with latest machines, such as High-speed CNC machines, EDM wire cut machines, Mirror finish capable sinker EDM machines, They are all imported from Taiwan, Switzerland, and Japan. These machines help us to ensure the molds are manufactured to the highest precision with a quality finish. Moreover, all of our processes are in-house, which allows us to accomplish short lead times, Our shop has 30 skilled toolmakers, most of whom have more than 10 years of mold making experience, they are familiar with all machining processes, the costs of each step can troubleshoot during the mold building process. Our staff is vitally important to our company, Their experience, and hard work allow Eco molding to guarantee a high-quality mold at a reasonable price.
