Injection Mold Tooling Service
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What is
Tooling in Injection Molding?
Get your injection molded parts created in the most innovative way. At RapidDirect, we offer custom injection molds that guarantee the success of your projects. We work with you to understand the peculiarities of your project, then develop a precise plastic injection mold design according to your specifications. Our expert technicians handle all complexities involved in the mold production process.
Our versatility allows us to develop prototype tools and production molds at affordable prices. With the fastest possible lead times, our capabilities help us optimize production and get your products to market faster. Are you ready to take plastic part production to the highest level? RapidDirect is ready to assist you in that journey.
RapidDirect
Mold Tooling Services
Rapid Tooling
Get easy design feedback and validation through superior quality prototype tooling. Create small batches of plastic molded parts with excellent injection molding prototypes. We excel at manufacturing prototype molds within days to ensure you perform functional tests and validate market interest. We implement affordable aluminum tooling to help you reduce financial risks before full-scale production.
Production Tooling
We create high-quality production molds for high-volume plastic parts production. With high-strength, durable tool steel material, our production tooling is suitable for producing hundreds of thousands of parts. We can vary materials and construction methods according to your unique requirements.
Types of Injection Molds
Ensure effective low-volume plastic parts production with high-quality single cavity injection molds. These cost-effective mold tooling options give you more control over the plastic manufacturing process.
Efficiently manufacture multiple plastic molded parts with superior-quality multi-cavity molds. Our multi-cavity injection molds ensure more effective use of cycle time while offering a lower cost of a unit part. With higher productivity, you can get high quantities of parts per cycle.
Increase the output of your injection molding process with innovative stack molds. RapidDirect delivers excellent stack mold tooling to increase your molding efficiency while reducing overall part cost. We can design stack molds with equal numbers or different numbers of cavities in each parting surface. Create multi-component assemblies in one shot!
Economical and efficient custom injection molding solution for molding two different plastic materials. We provide 2K injection mold tooling to allow a seamless combination of soft and hard plastics for one product. Save costs by creating tailor-made products and combining assembly steps into one molding process.
Materials for
Injection Mold
Types: P20, H13, S7, NAK80, S136, S136H, 718, 718H, 738
Types: 420, NAK80, S136, 316L, 316, 301, 303, 304
Types: 6061, 5052, 7075
Injection Molding
Capabilities
At RapidDirect, we design and create precise custom injection molds from high-quality materials. Our processes ensure unmatched consistency and repeatability at fast lead times and affordable pricing. Every plastic injection mold we fabricate meets international standards. From one-off projects to small batches and production tooling, we provide durable and reliable mold tools.
| Purpose | Shot Life | Tolerance | Cost | Lead Time | |
|---|---|---|---|---|---|
| Class 105 | Prototype Testing | Under 500 cycles | ± 0.02mm | $ | 7-10 days |
| Class 104 | Low-volume Production | Under 100.000 cycles | ± 0.02mm | $$$ | 10-15 days |
| Class 103 | Low-volume Production | Under 500.000 cycles | ± 0.02mm | $$$$ | 10-15 days |
| Class 102 | Medium-volume Production | Medium-volume Production | ± 0.02mm | $$$$$ | 10-15 days |
| Class 101 | High-volume Production | Over 1,000,000 cycles | ± 0.02mm | $$$$$$ | 10-18 days |
Design Guidelines for
Mold Tooling
| Description | |
|---|---|
| Radii | In CNC machining, sharp internal corners on a workpiece will naturally form rounded corners (radii). The depth must not exceed 12 times the diameter of the drill. For end mills, the depth must not exceed 10 times the diameter of the tool. |
| Threads and Tapped Holes | Diameter Φ 1.5-5 mm, depth: 3 times the diameter. Diameter Φ 5 mm or larger, depth: 4-6 times the diameter. RapidDirect can produce threads of any specification and size as required by the customer. |
| Undercuts | Square profiles, full radius, dovetail profiles. |
| Text | CNC Milling: Minimum width of 0.5 mm and depth of 0.1 mm. CNC Turning: RapidDirect can use laser marking to create standard text for CNC turned parts. RapidDirect can create standard text via CNC engraving or laser engraving as per customer requirements. |
Plastic Injection Molding Process
Plastic injection molding is a highly efficient and versatile process used to produce complex and intricate plastic parts.
1. Mold Design & Material:
Precision-designed molds are made using CAD software, typically from steel for durability or aluminum for faster cooling, depending on production needs.
2. Plastic Preparation:
Plastic granules are chosen for specific product properties, dried, and loaded into the machine’s hopper.
3. Melting & Injection:
The plastic is melted and injected into the mold under high pressure to ensure complete filling and detail accuracy.
4. Cooling & Solidification:
The molten plastic cools and solidifies in the mold, shaped by precisely controlled cooling channels to minimize defects.
5. Ejection & Finishing:
The solid part is ejected from the mold and undergoes any necessary trimming, polishing, or painting for final finishing.
6. Quality Inspection:
Each part is inspected for quality, ensuring it meets all specifications for dimensions, appearance, and performance.
Advantages of Prototype Tool
1. Speed to Market: Accelerates development and refinement, reducing time to launch.
2. Cost Efficiency: Less expensive than full-scale molds, minimizing initial investment.
3. Design Flexibility: Allows for easy modifications based on testing feedback.
4. Risk Reduction: Identifies production issues early, avoiding costly future corrections.
5. Functional Testing: Facilitates thorough testing to ensure the product meets all requirements.
FAQs
Injection molding tooling costs are high for various reasons.
Material Costs: Molds are typically made from high-quality, durable materials like hardened steel or aluminum. Steel is particularly costly but necessary for long production runs due to its durability.
Complex Manufacturing Process: Producing molds involves precise and labor-intensive processes, including CNC machining, EDM (Electrical Discharge Machining), and sometimes hand polishing. The complexity of the mold, including multiple cavities, undercuts, or intricate details, adds to the cost.
Precision: High-precision molds are essential for producing parts with tight tolerances, especially in industries like automotive, aerospace, or medical. Achieving this level of precision requires advanced manufacturing equipment and skilled technicians, which increases the overall cost.
Customization: Injection molds are custom-built for specific products, and each design demands unique considerations. This custom nature of the tooling, tailored to individual part requirements, significantly raises costs compared to more standard, off-the-shelf tools.
Design and Engineering Time: Developing a mold requires significant design work to ensure it can withstand high pressure and temperature during the injection process. The design must also account for part geometry, cooling channels, and ejection systems, requiring specialized engineering expertise.
Several factors affect the design:
Part Design and Geometry: The shape, size, and complexity of the part being molded greatly influence the mold design. Complex geometries, intricate details, and thin walls require specialized mold features, such as additional cooling channels or more advanced gating systems.
Material Selection: The plastic type significantly impacts mold design, affecting factors like cooling rates, shrinkage, and flow behavior. For example, polypropylene shrinks more, while polycarbonate requires higher mold temperatures. The mold material must also resist wear from abrasive or corrosive plastics.
Tolerances: Tolerances and Precision Requirements: High-precision parts require molds with tighter tolerances, which can complicate the design and increase manufacturing costs. Mold designers must account for dimensional accuracy and consistency, particularly in industries like automotive and medical.
Ejection System: The method of ejecting the part from the mold affects both mold design and cycle time. Options like ejector pins, air blast systems, or stripper plates must be carefully integrated into the mold to avoid damaging the part.
Gate Design: The location and type of gate (direct, pin, or edge gate) determine how the molten plastic enters the mold. Gate design affects the quality of the finished part, influencing flow characteristics, surface finish, and cycle time.
Undercuts and Parting Lines: Parts with undercuts or complex geometries may require side actions or lifters in the mold design to release the part without damaging it. These features increase mold complexity and cost.
FAQs
Die casting is a metal casting process characterized by forcing molten metal under high pressure into a mold cavity. The mold, also known as a “die,” is created using two hardened tool steel dies that have been machined into shape and work similarly to an injection mold during the process. Here’s how it works:
- Mold Preparation: The die is prepared and lubricated to facilitate the easy removal of the casting and to aid in controlling the temperature.
- Molten Metal Injection: Molten metal is injected into the die under high pressure, ranging from approximately 10 to 175 megapascals (1,500 to 25,000 psi). The pressure is maintained until the casting solidifies.
- Cooling and Solidification: The molten metal cools quickly in the mold, solidifying into the shape of the desired part.
- Ejection: Once solidified, the die halves are opened, and the cast part is ejected.
- Trimming: Excess material from the casting, such as gates, runners, and flash, is trimmed away.
When designing parts for die casting, several key considerations must be addressed to ensure optimal performance and manufacturability:
- Wall Thickness: Maintain uniform wall thickness to promote even cooling and solidification, reducing risks of defects like warping or internal stresses. Thin walls are preferred for faster cooling and material savings, but their feasibility depends on the metal used and part complexity.
- Draft Angles: Include draft angles in the design to facilitate the easy removal of the casting from the die. Typically, a minimum draft angle of 1 to 2 degrees is necessary, depending on the depth of the part.
- Fillet and Radii: Incorporate fillets and radii to eliminate sharp corners and edges, which can cause stress concentrations and crack initiation points. This adjustment also enhances the flow of molten metal within the die.
- Gating System: Design an efficient gating system to ensure proper flow of the molten metal into the die, minimizing turbulence and air entrapment. The placement of gates influences material distribution and part quality.
- Venting: Proper venting must be planned to allow air and gases to escape from the mold cavity during metal injection. This helps prevent porosity and incomplete filling.
- Simplifying Geometry: Simplify the geometry as much as possible to avoid undercuts and complex features that require intricate die mechanisms, which can increase tooling costs and complicate the casting process.
In die casting, vibrations refer to mechanical oscillations that occur within the die casting machines and molds.
Vacuum Pressure Casting: This process involves creating a vacuum in the mold cavity to minimize air entrapment and porosity. Vibrations in this setting can disrupt the vacuum, leading to defects in the final product.
Low Pressure Casting: Here, metal is introduced into the mold under low pressure, which can be susceptible to vibrations that affect the steady flow of molten metal, impacting the consistency and integrity of the cast.
Semi-Solid Die Casting: Involves injecting semi-solid metal into the mold. Vibrations can influence the thixotropic behavior of the metal, affecting the fill pattern and properties of the final part.
Squeeze Die Casting: This process applies additional pressure after the initial filling to enhance the density and mechanical properties of the cast. Vibrations during this phase can lead to non-uniform pressure application, resulting in inconsistencies.
The lead time for creating die cast tooling usually ranges from 2 to 12 weeks. This time frame starts from the initial design phase, where the concept of the part is developed and its specifications are detailed, to the completion of the mold. The complexity of the part’s design, the specific metal chosen for casting, and the precision required in the final product all significantly influence the duration of the tooling process. Additionally, after the mold is machined, it undergoes rigorous testing to ensure it meets quality standards. Any necessary adjustments or modifications to the mold to correct defects or improve functionality can add to the overall lead time. Effective communication between the manufacturing team and the client is essential to streamline the process and meet production deadlines.
Die casting is a precision manufacturing process that can achieve very tight tolerances, making it ideal for complex, high-volume parts. Generally, the tolerances for die casting depend on the dimensions of the part, the metal used, and the specific casting process. For standard dimensions, tolerances can range from ±0.1 mm for smaller dimensions under 25 mm, to ±0.5 mm for dimensions up to 250 mm. More precise tolerances down to ±0.02 mm can be achieved with additional post-machining processes.
Materials also play a critical role in defining tolerances. Metals like aluminum and zinc alloy have different shrinkage rates and mechanical properties, which influence the final dimensional accuracy. Advanced die casting techniques such as vacuum casting or squeeze casting can further enhance tolerance control by reducing porosity and improving the integrity of the metal.
Yes, post-machining of die cast parts is not only possible but often necessary to achieve the desired precision and surface finishes that die casting alone might not provide. Post-machining allows for the attainment of tighter tolerances and smoother surfaces, which are crucial for high-performance and aesthetic requirements. Common post-machining processes include drilling, milling, and CNC machining, which refine the features of the die cast part to exact specifications.
Additionally, post-machining can correct any minor defects that occur during the casting process, such as porosity or surface imperfections. It also enables the addition of complex features and fine details that cannot be achieved through casting alone. By integrating die casting with post-machining, manufacturers can leverage the speed and cost-efficiency of die casting for the rough shape, while achieving the precision of CNC machining for critical dimensions and finishes.
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