R & D
Product Design
We can help customer starting design from a concept or an idea. Once a concept is selected, proceed with developing a detailed design. This involves creating 3D CAD models of the plastic part using design software. Pay attention to features such as dimensions, tolerances, wall thickness, draft angles, ribs, bosses, and surface finishes. Ensure that the design aligns with the manufacturing capabilities and constraints of the chosen plastic material and production method (usually injection molding for plastic parts).
If customer provides us a sample of plastic part, we will do reverse design to create 3D model by 3D scanning. Reverse engineering is commonly used in various industries, including automotive, aerospace and consumer electronics. It enables customers to gain insights into competitors' products, troubleshoot issues, improve existing designs, or recreate obsolete components.
If customer provides us CAD drawings, our engineers will carefully analysis the drawings from manufacturing feasibility and optimize the design.
Mould Design
Mold design is a critical step in the manufacturing of plastic injection molded parts. It involves creating a detailed design for the mold that will be used to produce the plastic parts. Here are the key steps involved in mold design for plastic injection molding:
- Part Analysis: Start by analyzing the plastic part that needs to be produced. Understand its geometry, dimensions, wall thickness, draft angles, undercuts, and any other relevant features. Identify any potential challenges or design considerations for moldability.
- Mold Type Selection: Choose the appropriate mold type based on the part's complexity, production volume, and cost considerations. Common mold types include two-plate molds, three-plate molds, hot runner molds, and family molds. Each type has its advantages and limitations.
- Parting Line and Gate Design: Determine the parting line, which is the boundary between the mold's two halves. Select the gate location(s), which is where the molten plastic will enter the mold cavity. Consider factors such as part aesthetics, filling characteristics, and mold accessibility.
- Mold Cavity Layout: Decide on the number of cavities needed in the mold based on the desired production volume. Optimize the layout of the cavities within the mold to maximize productivity and minimize material waste.
- Cooling System Design: Design an efficient cooling system to control the temperature of the mold during the injection molding process. Proper cooling is crucial to achieve high-quality parts and reduce cycle times. Consider factors such as cooling channel placement, size, and uniformity.
- Ejection System Design: Determine the ejection system for removing the molded parts from the mold. This can include ejector pins, ejector sleeves, lifters, or stripper plates. Ensure that the ejection system does not interfere with the part geometry and allows for smooth ejection.
- Venting and Air Trapping Considerations: Incorporate proper venting to allow for the escape of air and gases during the injection molding process. Inadequate venting can lead to defects like burns, voids, or poor surface finish. Design vents strategically to prevent air trapping.
- Mold Materials Selection: Choose appropriate materials for the mold base, cavities, cores, and other mold components based on factors such as production volume, part material, and expected tool life. Common mold materials include tool steels, aluminum alloys, and beryllium copper.
- Draft and Surface Finish: Incorporate draft angles into the mold design to facilitate easy ejection of the part. Consider the desired surface finish of the part and incorporate texture or polish requirements into the mold design.
Moldflow Analysis
Moldflow analysis is a computer simulation technique used in the field of plastic injection molding. It is an important tool during mould design. It helps engineers and designers analyze and optimize the design of plastic parts and moulds before they are manufactured. By simulating the flow of molten plastic material into the mould cavity, moldflow analysis can predict various aspects of the injection molding process, such as filling patterns, cooling rates, shrinkage, warpage, and potential defects.
The analysis provides valuable insights into how the plastic material will behave during the injection molding process, allowing engineers to make informed decisions on part and mold design modifications. This helps improve the quality of the final product, reduce manufacturing costs, and minimize the risk of defects.
Key parameters evaluated during moldflow analysis include melt temperature, injection pressure, cooling time, gate location, and wall thickness. By adjusting these parameters, engineers can optimize the design to achieve better part quality, shorter cycle times, and improved overall productivity.
Overall, moldflow analysis plays a crucial role in ensuring the efficient and successful production of plastic parts through injection molding, helping to achieve high-quality products while minimizing manufacturing issues.
Simulations
Simulations play a crucial role in the design and optimization of plastic injection molds. They allow our engineers to predict and analyze the behavior of molten plastic during the injection molding process, identify potential issues, and optimize the mold design before manufacturing.
