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Injection Mold Make




We would like to share the basic injection mold making process in our company:


  1. Products design department provides product information to injection mold design department, injection mold designers complete cost analysis in two working days, and provide to R&D manager.

  2. R&D department release “Mold Making Apply” to plastic injection mold design department after confirmed the project.

  3. Injection mold designers organize relevant personnel to review the project base on the product information, including product structure, mold structure, cooling system, runner, slag, venting, etc.

  4. After eva1uation, injection mold designers begin to design the plastic injection mold, including 3D drawing correction, 3D parting, mold parts assembly drawing, EDM drawing, electrode drawing etc., and organize relevant personnel to eva1uate those drawings, then issue to plastic injection mold making department.

  5. Injection mold makers eva1uate and study the drawings, and order mold materials if there is no objection, otherwise, communicate with the plastic injection mold designers.

  6. Injection mold makers inspect the mold materials in time after the materials arrive to factory, and arrange technicians to do locksmith works, include turning, grinding, milling, screw holes, water carrying hole, center hole, CNC roughing, etc. The technicians should pay attention to the precision of each right-angle sides, avoid empty of the center hole and each production base, roughing margin etc. Then outsource each mold part to heat treatment promptly.

  7. After heat processing, injection mold maker must detect its hardness and metallurgical analysis. Generally, the core hardness 46-50HRC, for uniform distribution of 9 points, requiring its hardness differ is less than 1HRC. Metallurgical analysis should be done for the injection mold core prior to processing to make sure there is no segregation, scars, etc.

  8. Electrode processing, there are fine and rough processing, fine male spark is 0.08, rough male spark is 0.2 (subject to the actual situation).

  9. .Before finishing, mold maker must make right angle for the mold core, the vertical degree should less than 0.02 mm, finish degree 1.6.

  10. For wire cutting, please note that all parts’ base, enlarge 0.02mm for the insert hole and center hole as tolerance clearance, for non-standard thimble, the tolerance clearance is 0.04mm of the actual thimble size.

  11. Mold core finishing, shall base on the benchmarks after making right-angles, typically leaving 0.02 mm die as a margin (without considering tool wearing).

  12. EDM processing, process according to the drawings’ size, fine 0.08, rough 0.2 (subject to the actual situation), pay attention to the benchmarks in processing, for sparks processing, the leave a margin of 0.03-0.05 mm.

  13. The runner surface must be polished to achieve ▽6 or ▽7 finishing, the surface does not allow spark or knife pattern exists.

  14. Before assembling the plastic injection mold, the mold maker must do a comprehensive inspection for all related parts to make sure everything is in a good condition, and do cleaning and anti-rust treatment.

  15. In the mold tryout, injection mold designers, plastic mold makers should go to the site, making analysis and solution of abnormal in mold  tryout, improving the plastic injection mold and tryout process according to the results, and fill “Mold Tryout Report”.

  16. By 100-150 cycle time, the final product are defect-free, the production department make production schedule, the technicians track the production processes, and feedback yield to the plastic injection mold making department.

  17. After mold tryout, injection mold making department apply for storage with the forms of “Mold Making Apply” and “Mold Making Inspection”.

  18. The tryout samples will be sent to the customer for final checking and approving.

  19. After approving of the samples of the customer, the mold maker will do the final polishing and cleaning of the mold, spray the anti-rust agent to the mold surface, and pack the mold by film and exporting wooden box.

  20. Arrange the transportation or shipment to send the mold to customer’s place.

  21. Keep in touch with customer after customer receiving the new mold, and provide the timely guide and service.



Frequently used parts
Item
Brand or Supplier
Mold base steel
S45C,S50C,P20
Mold core and cavity
P2,718H,H13,NAK80,2316,S136,2344,etc
Hot runner systemSINO,YUDO,HUSKY,MASTER,HASCO,etc


Frequently used plastic material
Item
Brand or Supplier
PP
SNOPEC/ExxonMobil/LCY/SEETEC
ABS
SINOPEC/SABIC/LG/CHIMEI
PC,PC+ABS
SABIC/BAYER/KINGFA/MITSUBISHI
PA,PA+friber
DUPONT/DASF/EMS/DSM
POM
DUPONT/POLYPLASTICS
TPU
BASF/BAYER/SANTOPRENE
PBT
SABIC/BASF/POLYPLASTICS