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17 02, 2017

Some things about injection mold you may don’t know


Seven hundred pounds of hardened stainless steel. That’s the average weight of an injection mold. Some can weigh over a ton, some just a few hundred pounds, but any way you slice it, you certainly wouldn’t want one to fall on your foot. So how do you get this massive piece of metal to produce intricate plastic parts? It’s all in the tooling. Using CNC EDM machines to create the base of the mold cavitations, it is the work of the tool maker to refine the steel to exact specifications. Precision work on the cavities is only part of the equation. The tool must also include gating to allow for proper melt flow and vents to allow gas and air to escape. Without the proper placement of these key features, parts will be subject to imperfections. If you are working with a turnkey plastic injection [...]

14 02, 2017

Automotive Injection Molding by Spark


What Kinds of Components Can Be Made from Automotive Injection Molding? Plastics are hugely popular in the automotive industry because they are lightweight, easily made and highly durable. With the introduction of plastics into the automotive industry decades ago, mass production was made simpler and much more cost efficient. The list of components made from automotive injection molding goes on and on. Essentially, if it’s plastic, it can be made by plastic injection molding. Here are a few examples of plastic parts and components made this way: - General instrumentation, including the molding that holds it all in place - Housings for electronic module controls - Radio controls - Plastic interior surfaces - Faceplates and lenses - Splash guards and other exterior automotive features What are SPARK’s Capabilities for Injection Molding for Automotive? Everything from under-the-hood components to the features you see throughout the interior [...]

11 02, 2017

How much do you learn custom silicone rubber?


Custom silicone rubber is often used in many automotive, appliance, electronic, and aerospace applications where resistance to temperature extremes are necessary. Silicone Rubber has a lower tensile strength than most other polymer/elastomers. Solvents, concentrated acids and oils tend to break it down. Use of Silicone Rubber where extreme temperature resistance is not essential is discouraged because of cost. Spark Rubber Molding Increases Large Part Rubber Molding Capability Spark increased capacity and large part capabilities with the addition of two new hydraulic presses for transfer molding and compression molding. With platen sizes of 48" x 56" and 42" x 42" with 36" rams, Spark Custom Rubber Molding is positioned to meet all of their customer's transfer and compression molding needs. Spark Custom Rubber Molding creates quality custom rubber compression molding, custom transfer molding, custom rubber injection molding and rubber to metal bonding with the highest standards in [...]

8 02, 2017

A Focus on plastic injection molding


Two common defects caused by issues with the resin or resin additives used during injection molding are delamination and discoloration. Delamination Delamination, when a finished part has a layer of flaky material at the surface, hurts both aesthetic of your part and its strength. Caused by moisture contamination of the resin pellets or by other contamination of the melted resin with a dissimilar resin, or by release agents in the mold, delamination is the result of the resin being prevented from bonding. A number of methods, both simple and more complex, can be used to prevent delamination. If moisture is the issue, pre-drying the resin pellets or increasing mold temperature will help. If mold release agents are the cause, a mold redesign that places more focus on the ejection mechanism will help to eliminate mold release. If it is caused by cross-contaminated resins, that will [...]

23 01, 2017

How to make metal casting molds?(2)


Here I continue to introduce the process of manufacturing metal casting molds. Cutting the Gates Using a piece of sheet metal bent into a 1/2-inch-wide U shape, cut a channel, or gate, running from the casting cavity to the riser position. Lift out a bit of sand at a time, forming a gate slightly smaller than the diameter of the riser and slightly shallower than the depth of the casting cavity. Scoop out a similar gate from the casting cavity to the sprue position. For large molds, cut several gates to the sprue and the riser from various parts of the casting cavity. Blow out or tamp down any loose bits of sand in the gates. Refining the Mold Rebuild crumbled sections of the casting cavity by adding bits of moist sand, smoothing it into place with molding tools. Tamp down or blow away all [...]

21 01, 2017

How to make metal casting molds?(1)


We may need metal casting molds in many field. Do you know the process of manufacturing metal casting molds? Cutting the Sprue and the Riser To form the sprue — a passage through which you'll pour the metal — measure the depth of the cope, and mark this distance with tape on the side of a section of thin-walled 3/4-inch pipe. Push the pipe straight down into the sand in the cope, in a spot where it will not hit the pattern. Twist the pipe back and forth to cut an opening through the sand, stopping when the tape mark meets the surface of the sand. Use a slick to carve a funnel shape in the sand around the pipe, beveling the edges of the sprue opening. Then slip the pipe out, with the sand core inside, leaving a passageway through which you'll pour the [...]

16 01, 2017

Manufacturing mold by yourself or outsouring


If you want to manufacture silicone keyboard mold, many factors need examination. These include bottom-line costs, investments in molds, raw materials to run the parts, utilities, labor and overhead packaging. These factors are the foundation of the evaluation. Regardless of how your company allocates costs, at the end of the day, they are still true costs, and someone is paying for them. If you are an OEM thinking of outsouring your silicone keyboard mold manufacturing, the benefits are numerous. Here are just a few compelling reasons why you should consider using a control manufacturing (CM) 6 reasons that just make sense 1.Cost savings CMs reduce your overhead and labor costs. Focus your resources on what your company does well 2.Improve quality Look for ISO certified CMs. Certification signals continuous quality improvement 3.Flexibility CMs offer greater scheduling capacity. They can meet the needs of your market. 4.Time to [...]

16 01, 2017

Die Casting Consumer Parts


Die Casting Moldings are tools used in a process known as die casting. In this process, the metal alloy which can be zinc, copper or aluminum, is melted into liquefied metal by heating it in intense temperatures. After the metal alloy is liquefied, this will then be poured into the die casting tools and after it cools down, it becomes the finished product. This process is commonly used to create consumer parts. Consumer Parts Die Cast Tooling is the fastest and cheapest way to make bulk numbers of parts that are commonly used in everyday items. First of all, Consumer Parts Die Castings come in many forms, shapes and sizes. This process is very useful to many manufacturers around the world as aluminum die cast molding parts are used almost anywhere and everywhere. Automobiles rely heavily on aluminum parts, the same goes with lighting fixtures and [...]

11 01, 2017

5 main stages of die casting molding(2)


Here I will continue to introduce the remaining stages of die casting molding. 3. Cooling - The molten metal that is injected into the die will begin to cool and solidify once it enters the die cavity. When the entire cavity is filled and the molten metal solidifies, the final shape of the casting is formed. The die can not be opened until the cooling time has elapsed and the casting is solidified. The cooling time can be estimated from several thermodynamic properties of the metal, the maximum wall thickness of the casting, and the complexity of the die. A greater wall thickness will require a longer cooling time. The geometric complexity of the die also requires a longer cooling time because the additional resistance to the flow of heat. 4. Ejection - After the predetermined cooling time has passed, the die halves can be [...]

4 01, 2017

5 main stages of die casting molding(1)


The process cycle for die casting molding consists of five main stages, which are explained below. The total cycle time is very short, typically between 2 seconds and 1 minute. Clamping - The first step of die casting molding is the preparation and clamping of the two halves of the die. Each die half is first cleaned from the previous injection and then lubricated to facilitate the ejection of the next part. The lubrication time increases with part size, as well as the number of cavities and side-cores. Also, lubrication may not be required after each cycle, but after 2 or 3 cycles, depending upon the material. After lubrication, the two die halves, which are attached inside the die casting machine, are closed and securely clamped together. Sufficient force must be applied to the die to keep it securely closed while the metal is injected. [...]