According to customer needs or product design specifications, determine the basic parameters, material requirements, service life, etc. of the mold. Use computer-aided design software for detailed design, including mold structure design, part design, mold parting surface design, etc. Factors such as material shrinkage, molding process, and cooling system need to be considered during the design process. Select the appropriate material according to the mold type and usage requirements. Usually mold materials are steel (such as P20, 718, H13), aluminum alloy, copper alloy, etc. Perform necessary pretreatment of the material as required, such as annealing, tempering, surface treatment, etc., to improve the mechanical properties and service life of the material. Use CNC machine tools for precision machining, including turning, milling, drilling, grinding, etc. At the same time, EDM processes complex shapes and hard materials, and CNC machining can ensure machining accuracy and consistency. Through electric spark discharge, the material is eroded, which is suitable for the machining of mold cavities and detailed parts. Assemble the processed mold parts to ensure the matching accuracy of each part. Carry out trial molds to check the molding effect and product quality of the mold, and adjust and correct them after problems are found until the mold meets the design requirements. Conduct trial production to verify the molding effect and product quality of the mold, and make further optimization and adjustments based on the trial mold results. Deliver qualified molds to customers and provide necessary technical documents and operation manuals. Provide technical support and maintenance services during mold use to ensure the normal operation of the mold in customer production.
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What We Good At Mold Manufacturing Processes
Injection mold
Injection molds are tools used to mold plastic products. Molten plastic is injected into the mold cavity through an injection molding machine, and the desired shape of the plastic product is obtained after cooling and molding. According to the design drawings of the plastic product, its structure, size, material, surface quality requirements, etc. are analyzed. Use CNC machining centers, electrical discharge machining (EDM), wire cutting and other high-precision processing equipment to finely process the mold to ensure the dimensional accuracy and surface quality of each part. It is widely used in the automotive, electronics, home appliances, medical, packaging and other industries to produce various plastic parts and products. Injection molds play a vital role in modern manufacturing.
Roto-molding molds are special molds used in the rotational molding process (rotational molding process). The plastic raw materials are placed in the mold and rotated along two vertical axes during heating to evenly distribute and melt the plastic raw materials, and then form a hollow product after cooling.
Bottle blowing molds are special molds used to produce plastic bottles, mainly used in food and beverage, cosmetics, medicine, daily chemicals and other industries. For example, the production of high-quality, high-transparency plastic bottles, such as beverage bottles, cosmetic bottles, etc.
According to the design drawings of plastic products, analyze the requirements of structure, size, material, surface quality, etc. Use software to design the cavity and core, gating system, and cooling system. It is necessary to consider the manufacturing process, assembly process, service life, and maintenance convenience of the mold.
We use CNC machining centers, EDM, wire cutting and other high-precision processing equipment to finely process the mold to ensure each part’s dimensional accuracy and surface quality. We also use heat treatment processes such as quenching and tempering to improve the hardness and wear resistance of the mold and extend its service life.
A casting mold is a mold used in metal casting processes, mainly used to manufacture metal parts. Casting is the process of pouring molten metal into the mold cavity and obtaining metal parts with specific shapes and sizes after cooling. According to different casting processes, casting molds can be divided into sand casting molds, metal casting molds (such as die casting molds), investment casting molds, etc. Casting molds occupy an important position in modern manufacturing. The continuous advancement of their design and manufacturing technology helps to improve the efficiency and quality of metal casting production and meet the market demand for high-quality metal parts.
Sand casting mold is a widely used mold in casting process, mainly used to produce various metal parts. Sand casting process uses sand as the main molding material, creates the cavity required for casting through the mold, and then pours molten metal into the cavity to cool and solidify. It occupies an important position in modern manufacturing industry, and the continuous advancement of its design and manufacturing technology helps to improve the efficiency and quality of casting production.
Investment Casting, also known as lost wax casting, is a precision casting process used to manufacture high-precision and high-complexity metal parts. Wax Injection Mold is a key tool in this process, used to make wax models. It plays an important role in modern manufacturing. The continuous advancement of its design and manufacturing technology helps to improve the production efficiency and quality of metal parts and meet the market demand for high-quality metal products.
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Stamping mold
Stamping molds are tools used for sheet metal stamping. By applying pressure, the sheet metal undergoes plastic deformation or separation in the mold cavity, thereby obtaining parts of the desired shape and size. Stamping dies are widely used in the automotive, aviation, home appliance, electronics and other industries. Stamping dies occupy an important position in modern manufacturing. The continuous advancement of their design and manufacturing technology helps to improve the efficiency and quality of stamping production and meet the market demand for high-quality metal parts.
Silicone Mold is a mold made of silicone material, which has high flexibility, good demoulding performance and long service life. It is widely used in food, handicrafts, medical equipment, architectural decoration and other fields. Silicone mold is mainly used to manufacture products of various shapes and materials, especially products with complex shapes and fine textures. It occupies an important position in modern manufacturing industry. Its flexibility, high temperature resistance and good replication performance make it an ideal choice for manufacturing products with complex shapes and fine textures.
Optimize your designs to avoid unnecessary machining features, limit part complexity, help reduce manufacturing costs and time, and create machined parts faster and more efficiently.
How to choose the appropriate mold material
Common mold materials include steel, aluminum, copper alloy, etc. Steel molds are usually used for high production and high precision requirements, aluminum molds are suitable for small batch production and rapid prototyping, and copper alloy molds are used in situations where rapid heat dissipation is required. Consider the characteristics of the product material (such as plastic, rubber, metal) and choose the appropriate mold material and design.
How to properly solve the geometric design
Choose the parting surface reasonably to ensure that the part can be demolded smoothly when the mold is opened. The parting surface should be as simple as possible and avoid complex geometric shapes. All surfaces perpendicular to the parting surface should be designed with appropriate draft angles, usually 1° to 3°, to facilitate demolding. Keep the wall thickness of the part consistent and avoid sudden thickness changes to reduce shrinkage and deformation. Design fillets on all internal and external corners to avoid stress concentration. Usually the fillet radius should be greater than 1/2 of the wall thickness.
How to set up the cooling system of the mold
Design an effective cooling system to ensure uniform cooling of all parts of the mold and reduce the molding cycle time. The cooling pipeline should be as close to the mold cavity surface as possible, but it should not affect the mold strength. Water and oil are commonly used as cooling media. Choose the appropriate medium according to the mold material and product requirements.
How to set up the mold exhaust system
Set up exhaust grooves in the mold design so that the air and gas in the mold can be discharged smoothly to avoid bubbles and burning on the product surface. The exhaust grooves should be set at the highest point of the product and the last filled position. For complex molds, exhaust holes and exhaust needles can be designed to assist exhaust.
Requirements for mold assembly and debugging
The various parts of the mold must be assembled accurately to avoid looseness or misalignment during use. After the mold is manufactured, a trial mold is carried out, and the mold design is optimized through multiple debugging to ensure that the produced parts meet the requirements.
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Frequently Asked Questions
After the mold is used for a period of time, it is worn out. How to solve the problem of mold life?
Select high wear-resistant materials to manufacture molds, and perform regular maintenance and care to ensure that the mold operates in the best condition. In addition, optimize mold design and processing technology to reduce friction and impact.
What if the dimensional accuracy is not up to standard and the product is unqualified?
We use high-precision processing equipment and measuring tools to strictly control every link in the processing process. Carry out mold trial production, and adjust and correct dimensional deviations in time.
When scratches, dents and other defects appear on the mold surface, how to solve it, affecting the appearance and performance of the product?
We can improve the mold processing technology, use higher quality mold materials, and perform surface treatment (such as polishing, plating) to improve the surface quality of the mold.
How to solve the problem of unqualified products caused by deformation of the mold during processing or use?
Our engineers optimize the mold design, ensure the reasonable structure of the mold, select the appropriate heat treatment process, and reduce processing stress. Use high-strength materials to improve the rigidity and stability of the mold.
What should we do when problems such as flash, bubbles, and incomplete filling occur during the injection molding process?
We can adjust the injection molding process parameters such as temperature, pressure, speed, etc., optimize the mold cooling system design, and ensure uniform cooling. Check and maintain the injection molding equipment to ensure that the equipment operates normally.
What should we do when the mold is improperly installed or poorly aligned, resulting in product quality problems and equipment damage?
We can use special installation tools and alignment equipment to ensure that the mold is installed correctly. Regularly check and correct the mold installation position to prevent loosening and offset.
What should we do if the product sticks in the mold and is difficult to demold?
Our engineers can optimize the mold design, increase the demolding slope, and use efficient demolding agents or demolding devices. Regularly clean and lubricate the mold surface to prevent sticking.
What should we do when the mold cooling system is blocked or malfunctions, resulting in unstable product quality?
Regularly check and maintain the cooling system, remove blockages, and ensure smooth cooling water. Use corrosion-resistant materials to manufacture the cooling system to extend its service life.
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