A skilled team of design engineers will be able to brainstorm, design, and improve upon a variety of solutions to meet the particular complexities of a specific project. The design team at Creative Mechanisms has combined decades of experience creating elegant solutions to complex problems. Meet some of our team here, here, or here, or visit our Customer Testimonials page to see what previous and current clients have to say about our product design capabilities. We think you’ll be impressed.
After a looks-like, feels-like design has been tested and slated for further production, the mold (or die) needs to be designed for injection mold manufacturing. Molds are commonly made from these types of metals:
Hardened steel: Typically the most expensive material to use for a mold, and generally the longest-lasting (which can drive down price per unit). This makes hardened steel a good material choice for products where multiple hundreds of thousands are to be produced.
| SPECIFICATION |
HJF-140 |
| |
A |
B |
C |
| Screw Diameter |
Mm |
38 |
42 |
45 |
| Screw L/D Ration |
L/D |
22.1 |
21.6 |
19.5 |
| Shot Size(Theoretical) |
cm3 |
193 |
227 |
278 |
| Injection Weight(PS) |
g |
176 |
206 |
252 |
| Injection Rate |
g/s |
94 |
105 |
135 |
| Injection Pressure |
MPa |
205 |
159 |
140 |
| Screw Speed |
rpm |
0~220 |
| Clamp tonnage |
KN |
1400 |
| Opening stroke |
mm |
380 |
| Space Between Tie Bars |
mm |
420*420 |
| Max.Mold Height |
mm |
450 |
| Min.Mold Height |
mm |
170 |
| Ejector Stroke |
mm |
120 |
| Ejector Tonnage |
KN |
33 |
| Max.Pump Pressure |
MPa |
16 |
| Pump Motor Power |
KW |
13 |
| Heater power |
KW |
7.2 |
| Machine Dimension(L*W*H) |
M |
4.5*1.2*1.7 |
| Machine weight |
T |
4.2 |
| Oil Tank Capacity |
L |
230 |
Beryllium-Copper alloy: Typically used in areas of the mold that need fast heat removal or where shear heat is concentrated.
Just as with overall product design, mold design is another opportunity to prevent defects during the injection molding process. We have previously written blogs on the Top 10 Injection Molding Defects and Avoiding Mistakes in Injection Molding, but here are some examples of how poor mold design can be a costly mistake:
Not designing the proper draft: This refers to the angle at which the finished product is ejected from the mold. An insufficient draft can lead to ejection problems, costing significant time and money.
Improperly placed or sized gates: Gates are the openings in a mold through which thermoset or thermoplastic material is injected. Each will leave a vestige (scar), which can create aesthetic or functional problems if not properly placed.
The number of parts (cycles) required, as well as the material they will be made of will help drive decision-making as to how and with what materials to create the mold.
When a product has been properly designed, approved, and die cast, it’s time to start the actual manufacturing! Here are the basics of the injection molding process…
Thermoset or thermoplastic material in granular form is fed through a hopper into a heating barrel. (Learn more about the differences between plastics in our PLASTICS course.) The plastic is heated to a predetermined temperature and driven by a large screw through the gate(s) and into the mold. Once the mold is filled, the screw will remain in place to apply appropriate pressure for the duration of a predetermined cooling time. Upon reaching this point, the screw is withdrawn, the mold opened, and the part ejected. Gates will either shear off automatically or be manually removed. This cycle will repeat over and over, and can be used to create hundreds of thousands of parts in a relatively short amount of time.
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