Industrial Parts Plastic Molding Tools Plastic Molding Services abs injection

Product Specification

Industrial parts from Plastic injection tooling with PA/ABS material

Product Quick detail:

1. Cavity: 1 cavities mold

2. Molding Material: PC/ABS

3. Mold type: serial mold

4. Mold style:Big size mold

5. Mold base standard: Hasco

6. Runner system: Cold runner

7. Delivery terms: FOB

8. Mold life: 500K shots

9. Mold status: Complex mold

10. Cavity steel: 1.2083

Product specification:

1. Hot runner brand: YES
2. Gate style: Cold runner with side gate on the part
3. Ejection: ejector pins and sleeve
4. Mold unit: Metric tools
5. Surface finish: high polishing for visible side
6. Combining Moldflow analysis to optimize design
7. Combining DFM report to optimize design
8. Mold structure is safty and stable
9. Mold have sufficient air venting
10. Mold have sufficient cooling line
11. Mold produce the Part no defective, such like sink mark, bur mark, flow mark, flush etc
12. Scientific trial out to find optimum injection parameter
13. Every procedure follow ISO9001 strictly
14. Before tool shipped out no any sigle open opint
15. We will make the lifter and (inner) slider in these undercut position.

Product advantage:

1. Mold match customer injection machine
2. Mold is desgined follow customer standard
3. Mold is bulit with safest operation when production
4. Mold is in guarantee all over the word
5. 3 Parters in different area can deal it, in Mexico,Czech and Spain can provide after-serivice on the overseas.
6. Tool have been testing and pass the CPK.
7. Tool have been bulit in High Quality and short lead time with best engineering service

Product application:

1. Use for machinery
2. Use for electronic
3. Use for automotive
4. Use for information technology industry
5. Use for Space industry
6. Use for Medical industry
7. Use for Energy industry

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Issue Solution example:

Warping

Description: Warping (or warpage) is the deformation that occurs when there is uneven shrinkage in the different parts of the molded component. The result is a twisted, uneven, or bent shape where one was not intended.

Causes: Warping is usually caused by non-uniform cooling of the mold material. Different cooling rates in different parts of the mold cause the plastic to cool differently and thus create internal stresses. These stresses, when released, lead to warping.

Remedies:

1. Ensure that the cooling time is sufficiently long and that it is slow enough to avoid the development of residual stresses being locked into the part
2. Design the mold with uniform wall thickness and so that the plastic flows in a single direction.
3. Select plastic materials that are less likely to shrink and deform. Semi-crystalline materials are generally more prone to warping.

Burn Marks

Description: Burn marks are discolorations, usually rust colored, that appear on the surface of the injection molded prototypes.

Causes: Burn marks are caused either by the degradation of the plastic material due to excessive heating or by injection speeds that are too fast. Burn marks can also be caused by the overheating of trapped air, which etches the surface of the molded part.

Remedies:

1. Reduce injection speeds
2. Optimize gas venting and degassing.
3. Reduce mold and melt temperatures.

Jetting

Description: Jetting refers to a situation where molten plastic fails to stick to the mold surface due to the speed of injection. Being fluid, the molten plastic solidifies in a state that shows the wavy folds of the jet stream on the surface of the injection molded part.

Causes: Jetting occurs mostly when the melt temperature is too low and the viscosity of the molten plastic becomes too high, thereby increasing the resistance of its flow through the mold. When the plastic comes in contact with the mold walls, it is rapidly cooled and the viscosity is increased. The material that flows through behind that viscous plastic pushes the viscous plastic further, leaving scrape marks on the surface of the finished product.

Remedies:

1. Increase mold and melt temperatures.
2. Increase the size of the gate so that the injection speed becomes slower.
3. Optimize gate design to ensure adequate contact between the molten plastic and the mold.

Flash

Description: Flash is a molding defect that occurs when some molten plastic escapes from the mold cavity. Typical routes for escape are through the parting line or ejector pin locations. This extrusion cools and remains attached to the finished product.

Causes: Flash can occur when the mold is not clamped together with enough force (a force strong enough to withstand the opposing forces generated by the molten plastic flowing through the mold), which allows the plastic to seep through. The use of molds that have exceeded their lifespan will be worn out and contribute to the possibility of flash. Additionally, excessive injection pressure may force the plastic out through the route of least resistance.

Remedies:

1. Increase the clamp pressure to ensure that the mold parts remain shut during shots.
2. Ensure that the mold is properly maintained and cleaned (or replaced when it has reached the end of its useful lifespan).
3. Adopt optimal molding conditions like injection speed, injection pressure, mold temperature, and proper gas venting.

A large number of the defects mentioned above can be prevented in the design process by incorporating proper tooling design into the iterative process. Using moldflow software will help you identify ideal gate locations, anticipate air pockets, flow or weld lines, and vacuum voids. Most importantly, it will help you design solutions to these problems ahead of time, so that when it comes to production you do not have to worry about the defects costing you money.