The mass production of parts by injection molding

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If you have to produce a plastic product and you expect annual runs that exceed thousands of pieces per year, the solution is to make injection molds for plastic molding. The process involves the design and construction of the production equipment starting from a 3d file of the part that needs to be produced.

One of the assessments to be made in the 3d cad design phase of a plastic part is its industrial manufacturability. Beyond this, the designer must also evaluate how to design the mold in order to optimize costs. The choices made in this phase can significantly affect both the quality of the piece for aesthetics and functionality and the costs of the mold itself.

With an appropriate design of the mold it is possible to produce complex parts that have undercuts or that require the co-molding of metal inserts or the overmoulding of different materials (eg soft materials on rigid materials).

The choice of the mold production material is closely linked to the runs and the material that will be used for molding.

If the number of pieces to be produced is limited and the material to be used is soft (rubber, polypropylene or polyethylene), it is possible to choose aluminum for the mold base. If the production material for molding is hard or loaded, it is necessary to consider more carefully how to produce the mold as it may wear out quickly with production cycles. In these cases steel is almost always chosen.

Before starting the design and production of the mold we always recommend producing a 3D printing prototype to validate the design.

The design of the mold must take into account the specifications shared with the customer during the engineering phase in order to comply with all the technical, aesthetic, dimensional and economic requirements.

Experience allows us to identify the best technical solutions for the construction of molds in relation to:

  1. Material with which to build the mold between steel and aluminum
  2. Injection points and systems
  3. Post-molding extraction method
  4. Thermoregulation systems
  5. Sliding zones and movements of the mold
  6. Thermal treatments
  7. Surface finishes and embossing
  8. Use of prototyping for engineering validation

The constructive analysis of each point allows you to start an optimal production with great benefits for the customer.

In this case study, the customer chose to create a prototype before starting the design of the equipment. The model created in stereolithography was used for design, assembly, ergonomic and validation checks of the project as a whole.

This allows you to make all engineering changes on the product and avoid errors in the next phase, the design and construction of the production molds.

The production times of the mold are approximately 7-9 weeks, the first sampling is necessary for dimensional control and acceptance of the mold and after this first step we continue with the definitive molding.

HCA Kompact is a product of MAC3, a world leader in the design and production of accessories for level control, with the widest range of float switches, and for the automation of pumping stations.

Hydro Controller is a speed variator inverter with the following options:

  • for single pump and for groups.
  • on passage of water and air-cooled.
  • available with single-phase power supply for single-phase pump, single-phase power supply for three-phase pump (220V) and three-phase power supply for three-phase pump.

The interface has been specifically designed to facilitate the user experience and facilitate the display of the operating and alarm parameters. The parameters for commissioning are mainly the desired pressure and the maximum current of the pump; in case of anomalies HydroController protects the autoclave by switching off.

Thanks to MAC3 and all its staff for choosing COESUM in this project.

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