Manufacturing of injection molds is a very time-consuming process. Injection molds consist of many systems and components that must be made with high accuracy. For production, we use various methods such as CNC machining, EDM, grinding, and drilling. The selection of injection molding materials influences their production time and processing technology.
Injection molds are essential tooling for plastic production on injection molding machines. The injection mold manufacturing process is a multi-step process that requires precise design, the use of modern CAD/CAM tools and careful CNC machining. Many years of experience are also necessary.
The production of injection molds consists of several stages. First we analyze the detail (plastic product). This is followed by an analysis of the injection molding process, which is the basis for the requirements for injection molds. A mold design is then created, and materials and processing methods are selected . Based on the design, we have a set of components that must be made. Then we make the individual components of the injection mold. Finally, we perform the installation.
After assembly, we always test the mold by making a production run with plastic. Adjustments are then made on the mold and it is ready for mass production.
A variety of materials are used to make injection molds, with tool steel dominating due to its strength
The machining methods we use for mold making include cutting in steel, CNC milling, turning, grinding, drilling, polishing or EDM.
Injection molds are essential tooling for injection molding production. They consist of many components, as they must ensure accuracy and withstand the high pressure under which the plastic is injected.
They are characterized by a complex structure, including. Forming sockets, filler, cooling and ejection systems.
From design to implementation, each stage of injection mold manufacturing is critical to the successful implementation of the mold into the production process. Nothing is left to chance – from the product concept, analysis of the molded part model, preparation of the design of molding elements and the body, to the development of technical documentation and attention to aspects of mold design.
The injection mold manufacturing process is complex and involves many steps to ensure that the finished mold will precisely match the design requirements.
The shape of the mold determines the shape and workmanship of plastic products. Therefore, the final product must be the starting point of the injection mold design. Detail analysis is always the first stopper. It is necessary to anticipate potential problems, such as drafts, seepage or other defects that may arise.
The injection process defines the life of the mold, as well as the conditions of use.
The first step is to create an accurate mold design that takes into account all the requirements for the parts to be manufactured. Design is usually done using advanced CAD (Computer-Aided Design) software, which allows precise planning of sizes, shapes and technical details of the mold.
The mold design should be made for the injection of the target plastic. It is crucial to plan the shrinkage of the plastic for the mold, as every material has its own shrinkage.
The material from which the mold will be made must be selected to withstand the high temperature and pressure of the injection process, as well as to resist abrasion. The choice of material depends on a number of factors, such as strength requirements, precision or production costs. Also key is the information that the number of cycles the mold must withstand.
Tool steel is chosen for injection molding because of its high quality and strength. It offers excellent durability against working conditions, which translates into long-lasting mold life. Proper selection of tool steel alloys is essential to ensure the functionality of molds, which has a direct impact on the end result of the injection molding process. Tool steel is the most commonly used material, but not the only one. In addition to it, we also make injection molds in aluminum for prototype or short-cycle molds
For the manufacture of individual components, depending on the application, we select the appropriate peeling methods to ensure the form works properly. The methods fall into 3 categories:
Machining: Once the mold has been designed and the material selected, the machining process begins, in order to obtain the proper shapes of the mold components.
Heat treatment: Injection molds are often heat treated to increase their hardness and wear resistance. This process can include hardening and tempering.
Polishing and finishing: To ensure that the surface of the mold is smooth and the finished products are easy to remove, the mold can be polished. This can be done by hand or with machines.
What it is: CNC milling is a process in which material is removed from a raw block using a rotary cutting tool. CNC machines are computer-controlled, which allows them to track tool trajectories very precisely and produce complex shapes.
What it’s used for: In injection mold manufacturing, CNC milling is used to create main channels, cavities and other complex mold geometries that require high precision.
What it is: CNC turning is a machining process in which the material is rotated and the cutting tool moves along the axis of rotation, removing material. This is the opposite of milling, where it is the material that is static and the tool that rotates and moves.
What it’s used for: In injection mold manufacturing, turning is often used to machine cylindrical mold components such as mandrels and exit sleeves.
What it is: EDM is a process in which material is removed from a workpiece by means of a series of electric sparks occurring between the tool and the workpiece. This process makes it possible to process very hard materials and make very precise, intricate shapes.
What it’s used for: Electro-erosion is indispensable for creating intricate mold details, especially in hard materials that are difficult to machine by traditional methods. It is also used to introduce fine details and textures on the mold surface.
What it consists of: Drilling is a machining process that involves removing material with a rotary drilling tool, creating holes in the material.
What it’s used for: In injection mold manufacturing, drilling is used to create screw holes, cooling channels and other mounting and functional holes.
What it involves: Grinding is a finishing process that involves removing minimal amounts of material with a grinding wheel disc to achieve a very smooth surface or specific dimensional tolerances.
What it’s used for: Grinding is used in injection mold manufacturing for final surface finishing, ensuring a high level of smoothness and dimensional accuracy. This is crucial for mold components that directly affect the appearance and quality of injected parts.
What it is: Polishing is a finishing process that involves manually or mechanically smoothing the surface to achieve the desired smoothness or shine.
What it’s used for: In the context of injection mold manufacturing, polishing is used to achieve a very smooth mold surface, which is especially important when molding transparent or highly aesthetic parts.
Each of these methods has its own applications and is chosen depending on the design requirements, the mold material and the desired end result. The precise combination of these techniques makes it possible to produce injection molds of high quality and long life.
Injection molded products can have different finishes, depending on functionality and budget. The simplest is a smooth surface without additional treatments, which can leave minor imperfections.
To achieve other effects, such as polishing, texture, matte or anti-slip, additional processes such as electrodeposition, sandblasting, glazing or chemical etching are used. These operations increase the cost and production time of the mold.
After all machining is completed, the various parts of the mold are assembled. This step may also include the installation of cooling or heating systems, which are crucial to the plastic injection process, and injection systems.
Before mass production begins, the mold is tested to make sure it produces parts of adequate quality. This may require several injection tests and minor adjustments to the mold.
Prototyping and testing of injection molds is an important stage of production that allows to eliminate errors even before the start of mass production. As an experienced injection mold manufacturer, we perform specialized injection mold testing to help ensure that the mold will work properly in the production process associated with injection mold manufacturing.
As part of mold testing, manufacturers often run short test runs to verify the quality and accuracy of molded parts. This allows for possible corrections. To ensure that the injection mold is working properly, injection tests are conducted, which may include analysis of process conditions, such as temperature or pressure.
Based on the test results, the mold can be modified to improve quality or production efficiency. This could mean minor changes in mold design or injection process parameters.
Each of these stages requires specialized knowledge and experience to ensure that the finished mold will meet all requirements and produce high-quality parts.
Injection mold manufacturing is thus a process that combines engineering, design and precision machining.
The stages of injection mold manufacturing in China are exactly the same as locally. Manufacturing in China involves longer transportation times. The prototyping stage can take longer, as air transportation of prototypes takes several days. However, it is important to note that the mold making time in China is shorter than in the European Union.
It is worth remembering that injection mold manufacturing in China is attractive because production costs are much lower than in many other countries, so significant savings can be achieved. We’re talking about up to 40-70% lower mold production costs.
Injection mold manufacturing is a complex and demanding process, involving many steps – from part analysis, mold design, material selection, to fabrication and testing. It begins with a precise analysis of the final product, which is essential for designing a mold capable of producing a part without defects. The use of modern technologies such as CAD/CAM software and CNC machining, EDM or polishing methods is key to achieving high precision and quality.
The mold design must take into account the shrinkage of the plastic and be tailored to specific production requirements. Tool steel is often the material of choice for its strength and resistance to working conditions, but for prototype molds or those with short life cycles, aluminum is also used.
A variety of machining methods make it possible to precisely manufacture mold components, and their choice depends on the complexity of the design and the required accuracy. Assembly is the critical stage where all the components are put together. The testing and prototyping carried out allows for the detection and correction of any errors before mass production begins.
Injection mold manufacturing in China offers significant cost savings while maintaining similar production steps, despite longer shipping times and potentially longer time for the prototyping stage. This option is attractive to companies looking for ways to reduce production costs without compromising on quality.
Injection mold manufacturing begins with an analysis of the part and the injection molding process, which is the basis for determining the requirements for the mold. Design of the mold, selection of materials and processing methods follow. The individual mold components are followed by an assembly stage, and the whole process ends with testing the mold by making a production batch of plastic. If the need for corrections is detected, the mold is modified before mass production begins.
Most often tool steel is used for injection molding due to its high quality and strength. The tool steel offers excellent resistance to the high temperatures and pressures of the injection process, as well as to abrasion, resulting in long-lasting mold life. In some cases, for prototype or short-life cycle molds, aluminum is also used.
Prototyping and testing are essential to ensure that the mold is capable of producing parts of the right quality and according to design requirements. These stages make it possible to detect and correct potential mold problems, such as drags, overmolding or other defects, before mass production begins. This will help avoid costly mistakes and ensure that the production process runs smoothly and efficiently.
Write us what product you need,
and we will contact you within 1 hour!
office@injection-molds.eu
Plastipol Poland Sp. z o.o.
Zawadzkiego 68/7, 71-246 Szczecin
VAT: PL8522664660
KRS: 0000849574
© 2024 Injection Molds
Realization: AdWise
