To manufacture injection molded parts, we will have to consider a lot of things, but there some basic factors that we need to pay more attention and be carefully aware of. These factors are very basic, but sometimes we still get confusing, or even mistakes. That is the reason why we still have to consider more to start off on the right track.
1. Design
Most of big problems of injection molding are from design, that is the reason why proper design for the process will bring us successful injection molding programs. In this case, it is for rapid production.
We can break a larger part down into some or many smaller pieces, then assemble them, which can help us to get shorter lead time. Because, we can produce quicker shallow cavity designs via the CNC machining process. It is great to start with a “Straight Pull Mold” for designing moldable parts. To do this, we have to get all the part’s features designed, so that when we pull the mold’s two halves from each other and the part is ejected, this does not require secondary processes.
This is due to mold material’s tendency to pull through part plastic (this is referred to as an ‘undercut’.) Undercuts require mold pieces to pull out sideways, perpendicular to the direction of the pull. These ‘side actions’ as they are called can require ‘hand loads’ for lower volume projects or automatic/mechanical loads for higher runs.
2. Material
In order to get ideal quick turn project, we should utilize standard, off the shelf colors and materials that either our have already in your warehouse, or we just simply source from a material supplier. Generally, name brand material is not so necessary, which does not cause issues. However, it is not true for all projects!
Once a specific brand and type of material is mentioned, or even required, we can order and get the material shipped while we are processing tool cutting simultaneously. If the material does not arrive within the alloted window, sometime we can use a substitute material in place of the production material, at the very least, confirm basic design and function of the part. Once production material arrives, a second sample run can take place before proceeding with higher production runs.
3. Cost
When we get a project that is required with a lead time for parts quicker than our standard, we should consider the cost. These considerations are driven by additional man hours required by the project up front and often result in overtime and extended shop hours to achieve the desired ship date. Those items that can be sped up? Things such as tool design, steel or aluminum delivery to the shop, part material ordering, and scheduling sample production runs.
It is important to remember that in many cases, all the money in the world cannot speed up certain processes. Cutting of the core and cavity, for example, is at the mercy of the almighty CNC machine. So while there are things within a tooling shop’s control, other things will always have a fixed lead time. This is why those factors mentioned become even more important to reduce the number of days to the finish line.
(Reference from Quickpart's blog)
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Bluestar Technology Group Co., Ltd
Plastic Injection Mold Making - Automotive Plastic Part Production
Homepage: www.bluestar-mould.com Tel: 0086 755 2689 0382
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