A Detailed Insight of Design, storage and Machining of Custom Mould

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Injection molding is basically a manufacturing process for the production of parts by injecting certain materials into the mold. A mold also known as die are the most common terms which are used for describing the tools which are used to produce the plastic parts in the molding process. As molds have been quite expensive to produce, they were generally used only in mass production wherein over thousands of parts were produced at once.

Mostly molds are made from hardened steel, aluminum or beryllium-copper alloy. However, these days the plastic mold factory can customize the molds according to the need of the customer.

Design of the Mould

The mold has two primary components namely the injection mold and the ejector mold. These components are often also known as moulder or a mold maker. The plastic resins enter the mold through a gate in the injection mold. The purpose of the sprue brushing is to seal tightly against the injection barrel’s nozzle of the molding machine. Its purpose is also to allow the molten plastic to flow from the barrel to the mold which is also referred to as a cavity.

The amount of the resin required for filling the sprue, cavities and the runner of the mold consists of a shot. Any trapped air present in the mold can escape through the air vents which are present in the mold's parting line or somewhere around the ejector pins and the slides which are comparatively smaller than the holes which retain them. In case the trapped air does not escape, it gets compressed by the pressure of the material that is incoming and gets squeezed in the corners of the cavity. This, in turn, can prevent the filling as well as several other defects. The air at times can become so compressed that it ignites and then burns the plastic material that is surrounding it.

Mould Storage

The manufacturers have to go to great lengths in order to protect the custom molds because of their rather high average costs. The humidity and an appropriate temperature are maintained so as to ensure the longest lifespan possible for each of the molds. Molds for the purpose of rubber injection molding are stored in a temperature controlled environment in order to prevent warping. 

Machining

Molds are built mainly through two methods namely standard machining and EDM. Standard machining has been used historically as a method to build injection molds. The EDM, on the other hand, has become popular recently for mold making. The process allows shaping of the pre-hardened mold so that there is no requirement of heat treatment. 

The custom molds require a lot of care as their cost is comparatively higher. HQMOULD uses tools of steel for manufacturing these molds.

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