Design is arguably the most critical aspect of any manufacturing process to get right from the beginning. With injection molding, expertise in mold design will streamline the entire process.
Plastic injection mold design entails making considerations for not only the mold, but the future product itself. Learn more from GAIM Plastics in our step-by-step guide to plastic injection mold design.
Identify Core Requirements
The initial steps in plastic injection mold design will have the manufacturing company’s design and engineering team work alongside your team to identify the core requirements of both your mold and, subsequently, the injection molded component that will be manufactured.
Core requirements to identify can include: part application, materials for the mold and injection molded components, anticipated production volume, and any aesthetic considerations such as embossing or part decorating.
Design for Manufacturability
When design and engineering teams utilize design for manufacturability concepts, it’s one of the surest ways to ensure that your mold and, by extension, your injection molded components, are easily manufacturable. Key considerations to make for DFM best practices include:
- Uniform wall thickness to avoid defects such as warpage and sink, and promote cost-effectiveness measures such as shorter cycle times.
- Make considerations to add as many drafts as possible so the component releases cleanly and easily.
- Rounded corners are recommended to minimize stress and flow problems.
- Incorporate both ribs and bosses to reinforce the injection molded part without needing thick sections that could weigh down the part.
Plastic Injection Mold Design Architecture
In this step, the focus is on one of the most costly aspects of injection molding, but also the most important. The tool layout of injection molding can make all the difference, as properly planned and manufactured tool layouts and dies can last for several cycles and reduce the cost-per-part dramatically.
When focusing on the mold architecture, keep these aspects in mind:
- Core and cavity
- Parting line
- Spruce
- Runners
- Gates
- Vents
- Cooling channels
- Ejection systems
Perform Mold Flow and DFM Review
Once all of the considerations for the mold, DFM incorporations, and mold architecture have been made, it’s time to put them to the test by running mold flow simulations and a DFM review.
A mold flow simulation demonstrates how the mold will be filled during injection molding. While only a simulation, with the advancements in technology available, it can show potential problem zones within the mold and where defects are likely to occur. Simultaneously, DFM review is performed prior to cutting the steel for the mold to highlight where potential problems exist, such as air traps, weld lines, short shots, and uneven filling.
Machining and Assembly
After all initial and intermediate reviews of the mold have been completed, your manufacturer can begin machining and assembly of the mold itself. With the initial manufactured tooling and mold, manufacturers are able to truly gauge where any potential problems will occur during production by viewing essential aspects of the mold, such as surface finish, alignment, ejector action, and cooling connections.
Sampling Validation
If, after machining and assembly, the mold has hit the mark and is deemed usable, there is one more validation before the production run. A trial production run using the mold is performed, where actual shots are filled into the cavity, or cavities in a multi-cavity mold.
If the ejected parts don’t show any defects, actual production can begin. If there are defects, design and engineering teams review the injection molded components to gauge where the defects occurred during the sampling process.
Additionally, maintenance programs can begin to form for the mold after seeing how it endures the sample manufacturing process.
For More Tips on Plastic Injection Mold Design, Contact GAIM Plastics Today
Since 1989, GAIM Plastics has been a pioneer in the injection molding industry. Proudly located in Elmhurst, Illinois, our team of skilled technicians and expert, knowledgeable engineers has the experience to take the most complex injection molding projects from concepts to completed jobs.
Plastic injection mold design is one of the capabilities we do best with our development program. Our three-step process starts off with an initial consultation where our team sits down with yours to discuss the entirety of your project and iron out the details. From there, we design the mold and tooling aspects, and even incorporate our rapid injection molding prototyping capabilities.
Have a design ready to go or interested in more tips on design? Contact GAIM Plastics today, and let’s take your project from concept to completion.