10 steps of AMSL injection mold-making process:
1. Accept the mission
- Analysis the latest product drawing
the use and process of the product. - Analyze the geometric characteristics of the product
- Analyze the dimensional accuracy of the product
- Analyzing the surface quality of products.
- Determination of molding process.
- Determination of molding equipment.
- Calculating and checking the size and strength of molded parts and other structures.
- Primilary design for manufacturability ( DFM )
2. CAE analysis (mold flow analysis)
Mold flow can help us to predict and analyze the flow; cooling and warping behavior of plastics in the mold. it can be used to optimize the mold design and improve the molding quality of plastic parts. Normally we perform the mold flow analysis but in the following situations no need perform this process :
- When the mold design and manufacturing process is very simple, and there is no complex features or structures.
- When the plastic material, mold temperature and molding process are very stable and highly predictable.
- When there are no special requirements for the quality and performance of the plastic
3. Mold design
- Determination of the cavity numbers ; shrinkage rate and the product layout
- Determining the size of the mold base, including the size; guiding mechanism and position mechanism and other auxiliary institutions.
- Design the mold structure. design the parting line; injection system; sprue; sprue bushing; gate size;
- Design of cavity and core.slider, core-pulling and lifters;
- Determination of ejection system (cooling and heating systems) and exhaust system
- 3D modeling and 2D GA design and processing
4. Ordering main materials
Release the mold design for production. procurement for mold base; mold steel; standard parts etc..
5. Inspection for all of the incoming materials
To ensure the quality of injection mold raw material meets the requirements, improve production efficiency and product quality.
- Check dimensional accuracy ( measure various dimensions including length, width,thickness and other critical parameters
- Surface quality ( inspect the raw material surface such as scratches, pits, cracks or stains these defects can affect the performance and durability of the tooling )
- Mechanical Properties ( examine the mechanical properties of the injection mold tooling material, including tensile strength, yield strength,hardness and impact resistance. )
- Material composition ( verify the purity and alloying elements of the material )
- Physical properties ( such as the density, specific gravity, thermal expansion coefficient, and conductivity )
- Heat resistance
6. Mold manufacturing
The mold making process requires various types of equipment to ensure accurate and efficient production. Here are some commonly used mold making equipment: CNC machine ;EDM; wire EDM machines; grinding machines; Drilling machines; milling; lathe machine and mold polishing equipment.
The specific equipment required may vary depending on the complexity and size of the mold being produced.
8. Mold tryout
Mold tryout refers to the process of testing the new molds, to ensure the functionaly and reliability before it is put into production…..
9. Mold Acceptance
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10. Mold delivery
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