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Before the mound design, our engineers will do the DFM Analysis, to identify and fix any problems that might happen in the manufacturing phase to reduce the risks. It contains wall thickness analysis, feed system analysis, weld lines and sink marks estimate and so on. It can help us to precisely define various tolerances, rules and common manufacturing checks.
The design is started with a 3D layout, basic information will be present, such as mold size, gating way, parting line, ejection way, cavities and cores layout, mold base and accessories, etc. 2D in details and NC programming will follow after the 3D design is approved by the customer. Generally, a complete mold design would need 3-7 work days. Some of the complex projects require mold flow analysis or frequent updates of custom design, it could take much more time.
Mold base and mold steel can be purchased immediately after the design is confirmed, accessories especially hot runner, could take much longer time to get back.
All incoming raw materials are verified. Our Quality Control team would do the inspection of dimensions, hardness to ensure molds long life.
The mold steel need first to be sized, milling, drilling, wire cutting are the main process way to get the rough shape or the cavity /core. Normally 0.15-0.3 mm steel left for precision machining later.
To get high precision dimensions, many dies are machined with our 5-axis machine to cut across X, Y and Z axes along with rotating on the A and B axes. 5-axis CNC machining enables us to do the most complicated mold designs for our clients.
Wire cut is a process specially for holes (ejector pin holes, lifters, inserts), EDM is particularly for some of the area where conventional metal removal is difficult or impossible machined by normal way, either too small to allow the cutting tool work properly, or it’s too narrow to get there.
Mold fitting is a critical step of mold making procedure. Depending on workers experiences and skills, some of the components need to be polished to fit, or the core / cavity have specially requirement for surface finish, such as texture, polish, engraving.
Mold trial would be arranged after the mold assembly finished, it is also an important step, and requires comprehensive understanding of mold knowledge.