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Mold Building

The mold building process for injection molding involves several key stages and activities:

Pre-production Preparation for Mold Manufacturing

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  • Mold Design Review

    Placeholder ImageMold Design Review

     
    1. Before opening the mold, a comprehensive review of the mold design is required. The participants in this review typically include mold designers, product designers, and injection molding process engineers. The review checks whether the mold structure is reasonable and if it meets the product’s molding requirements, such as the suitability of the parting line for easy product ejection, and the appropriateness of the gate location to ensure product quality and appearance.

    2.Evaluation of the cooling system and ejection system design is crucial. For example, ensuring the cooling system can effectively control the mold temperature to prevent defects like deformation or shrinkage, and that the ejection system can smoothly eject the product without causing damage.
  • Material Procurement

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    Material Procurement

     
    1.According to the mold design requirements, appropriate mold steel is procured. Various types of mold steels are available, such as P20 steel, which is commonly used for general injection molds due to its good machinability and moderate wear resistance, or H13 steel, which is used for molds requiring higher strength and thermal stability, such as die-casting molds or molds for high-temperature plastics.

    2.Standard components such as guide posts, bushings, and ejector pins are also procured. These standard parts directly affect the mold’s accuracy and service life, so it is important to select reliable suppliers and ensure that the parts meet the design specifications.
  • Preparation of Processing Equipment

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    Preparation of Processing Equipment

     
    1.Various equipment, such as CNC machining centers for processing complex cavities and cores, EDM (Electrical Discharge Machining) machines for creating parts with special shapes (e.g., deep holes, narrow grooves, complex undercuts), and surface grinders for high-precision flat surfaces, need to be prepared.

    2.Equipment must undergo calibration and precision checks to ensure that the machines operate correctly and meet the required tolerances for mold manufacturing. For example, CNC machine tool calibration includes verifying tool compensation parameters and coordinate axis accuracy.

Mold Component Machining

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  • Rough Machining

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    Rough Machining

     
    1.Large cutting tools and cutting parameters are used to quickly remove the majority of the mold’s excess material. For example, a large milling cutter is used to perform rough milling on large mold plates, bringing the material close to the final shape, leaving 0.5 - 1 mm of material for subsequent finishing.
    2.During rough machining, it is important to balance machining efficiency and tool life. Proper cutting parameters, such as cutting speed, feed rate, and depth of cut, should be set to avoid excessive tool wear or damage.
  • Finishing

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    Finishing

     
    1.Smaller cutting tools and cutting parameters are used for high-precision machining of mold components. For example, ball-end mills are used for three-dimensional surface machining of cavities and cores to achieve the required dimensional accuracy and surface roughness.
    2.Precision control is critical during finishing. Online measurement systems or offline inspection equipment, such as coordinate measuring machines (CMM), should be used to inspect the dimensions of machined parts and adjust processing parameters in real-time to ensure part quality.
  • EDM (Electrical Discharge Machining)

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    EDM (Electrical Discharge Machining)

     
    1.When parts of the mold have shapes that are difficult to process using traditional methods, such as deep narrow grooves or complex undercuts, EDM is used. This process erodes metal material by applying high-temperature pulses between an electrode and the workpiece.
    2.Electrodes are designed and made according to the shape to be processed, with copper or graphite typically used as the electrode material. During the process, discharge parameters, such as discharge current, time, and gap, must be precisely controlled to ensure machining accuracy and surface quality.

Mold Assembly

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  • Part Cleaning and Inspection

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    Part Cleaning and Inspection

     
    1.Before assembly, all mold components must be cleaned to remove any residual oil, metal shavings, or contaminants from the machining process. Suitable cleaning solvents like gasoline or specialized metal cleaners are used to ensure that the parts are clean.

    2.After cleaning, components should be inspected for dimensional accuracy and shape, ensuring they meet the design requirements. Non-compliant parts should be reworked or discarded.
  • Component Assembly

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    Component Assembly

     
    1.The basic components such as guide posts and bushings are installed first. These components must have high precision to ensure proper alignment. The gap between the guide post and bushing is typically between 0.01 - 0.03 mm to ensure accurate mold opening and closing.

    2.Next, the core and cavity are assembled. The assembly must ensure the correct fit and gap between these parts. For high-precision molds, the gap between the core and cavity may be as small as 0.03 - 0.05 mm, and concentricity and positional accuracy must be ensured.

    3.The cooling and heating systems are also assembled, making sure that all pipes are tightly connected without leakage. The cooling channels should be checked for blockages to ensure smooth cooling.

Final Assembly and Debugging

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1.Assembly of Mold Components: After all components are assembled, the mold should be thoroughly checked for installation order and direction. For example, ejector pins and ejector plates should be installed in the correct sequence to ensure smooth operation.

2.The mold should undergo debugging by opening and closing the mold to check for smooth operation. Any interference between moving parts should be identified and corrected. Manual and low-speed machine operation methods can be used for debugging.

Mold Trial and Optimization

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  • Material Preparation for Mold Trial

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    Material Preparation for Mold Trial

     
    The same plastic material used in actual production should be selected for the mold trial. The material’s properties, such as flowability and shrinkage, significantly affect the trial results. Additionally, materials should be properly dried to prevent defects like bubbles or silver streaks, especially for hygroscopic materials like nylon (PA).
  • Mold Trial Process

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    Mold Trial Process

     
    1.The mold is installed on the injection molding machine, and parameters such as injection pressure, speed, holding pressure, holding time, and cooling time are adjusted. Several mold trials are conducted to observe the product's molding performance, checking whether the product is complete, whether the appearance meets requirements, and whether the dimensions are accurate.

    2.Each trial’s parameters and product performance should be recorded, and any issues should be analyzed. For instance, if flash is present, it may indicate excessive injection pressure or insufficient mold clamping force, while sink marks may indicate insufficient holding pressure or uneven cooling.
  • Mold Optimization

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    Mold Optimization

     
    1.Based on the issues identified during the trial, adjustments are made to optimize the mold. For example, the gate size and location might be adjusted to improve melt flow, or the cooling system could be improved to optimize temperature distribution.

    2.After several rounds of optimization, the mold should reach a stable production state, capable of consistently producing products that meet quality standards.
Professional-Team-

Professional Team

 
More than 20 years practical experience in mold /tools design ,injection, manufacturer.
Professional material procurement team to ensure timely and fast delivery.

Advanced Equipment

 
The precision of machining equipment can reach ±0.005, far exceeding its peers.
Equipped with advanced foreign production and testing equipment.
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Technology Advantages

 
With a large product database, the entire precess is traceable.
Senior design engineers & experienced technicians work together to reduce processing detours.

Superior Quality

 
Perfect quality system with one-stop management of personnel, equipment and systems.
Strict process control and fully automatic robot operation contribute to high quality and pass rate.
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Quick Reply

 
With professional team ,blector can reply quickly for mold /tools and injection.
Single and double injection mold can be quickly tested, & blector is with efficient production capacity which can meet the requirement of our customer.

Excellent Service

 
Provide professional and high quality service, high-quality and efficient pre-sales and after-sales.
Affordable price, on-time delivery, and protection of customer rights.
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