This You Tube Video discusses the basics of injection mold design. Modern injection mold design includes many features which are discussed in simple to understand terms.
INJECTION MOLD STEEL DESIGN TIPS – WHAT STEEL SHOULD YOU USE WHEN BUILDING YOUR NEW PLASTIC MOLD?
November 21, 2011 by
Building Your New Plastic Injection Mold
Your company is about to invest in a mold to manufacture a plastic part. That is, you’re ready to write the purchase order once you decide which molder has quoted you the best value for your dollar. You want the lowest price, the lowest mold maintenance, AND the highest product quality. Right? Yet, how can you tell what you’re really buying when one supplier quoted $3000 and another quoted $13,000? They both saw the same blueprint! It’s probably true that both molds could produce good quality plastic parts.
Injection Mold – What Steel to USE?
Buyers should consider two scenarios: quick machining steel/low production quantity versus slower machining steel/high production-high quality. Quoting molds is often an “assumption game.” The more the customer can define what they want, the fewer variables enter into the quote. The customer’s goal is to get apples-to-apples quotes from each supplier, and this isn’t always easy.
One variable in quoting the mold is the quality of steel to be used. Total Solution Plastic typically quotes high quality tool steel unless the customer specifies otherwise. We do, however, build tooling from all grades of material such as prehard steel (P-20), hardened tool steel (S-7,H-13,O-1,A-2,etc.), or stainless steel. When dealing with Asian suppliers, it is also important to understand the country of origin of the steel. Even though it meets the industry standard, doesn’t mean all steel is the same.
Prehard: P-20
P-20 is the most popular and versatile mold steel. It is used for all sizes of machine-cut molds, and does not require post machining heat treatment. No heat treatment eliminates the finish machining and grinding operations which are necessary because of the dimensional changes which occur in heat treatment.
Prehard can be chrome-plated or nickel-plated for wear and corrosion resistance, if needed. However, we typically do not recommend P-20 steel if the production quantity is high (+500,000) or reinforced plastics are to be used. The trade-off is usually less mold builder labor ($) versus longevity of the mold (time).
Hardened Tool Steel: H-13, S-7
This steel renders a fine combination of toughness and strength. The steel is mostly furnished in the annealed condition and must then be heat treated after the mold is finished. The steel hardens to about Rockwell C 46 – C 54. Hardened tool steel is used when a steel is needed for molding reinforced plastics, or when a large production quantity is anticipated. Hardened steel also takes an excellent polish, therefore it is used for clear parts such as lenses.
Stainless Steel: 420
Stainless steel is frequently used when corrosion or rusting may be a problem. Rusting of waterlines or the mold due to condensation can be very costly because of the extra maintenance and frequent polishing. Stainless 420 must be heat treated. It has outstanding dimensional stability in heat treatment and therefore, the mold needs very little finishing and correcting after heat treatment. This steel also takes a high luster polish.
Three variables enter into the calculation of a mold’s price: the material to be used, the estimate of mold maker hours, and the labor/overhead rate.
Price = Material + (Hours X Rate)
The steel quoted will determine the material price and mold builder hours required. Although the steel or material cost typically amount to only 10% of the mold’s price, the amount of time required to machine the steel is a major part of the cost. The prehard steel may be a very cost effective route if for example, the plastic to be molded is polyethylene, the quality of the plastic part is not “gold-plated”, and the life of the mold is small, such as 10,000 pieces.
If, on the other hand, the plastic part is 30% glass-filled nylon, specifies no parting line flash, and will run one million parts, Total Solution Plastic will quote the tool steel you request.
The challenge for all buyers is to define which steel is being quoted and whether that steel will be satisfactory for the project’s objectives.
Getting your best buy for Injection Molds?
November 21, 2011 by
All of the folks at Total Solution Plastic speak English (although it is with a “southern” accent)! We are located in Raleigh, NC and have been importing Injection Molds from our sister company in Shenzhen China for +11 years. We stand behind our products and have a superior reputation in the industry! Please visit us at www.totalsolutionplastic.com. We understand “the total cost of acquisition of injection molds”!
Are your projects on time when procuring injection molds for Asia?
November 19, 2011 by
Procuring Injection Molds for Asia
Total Solution Plastic has experienced in the past week an earthquake, tornadoes, a hurricane and a +500 point swing in the market. Is there something here that Nostradamus predicted? I certainly hope not, but the good news is that we are all doing well and suffered very little damage here. We pray for those that were affected by these disasters.
Many have suffered the past couple of years due to the market conditions. I am not going to attempt to predict the future, but we have certainly seen a sharp increase in activity and orders. We have seen spurts of business previously, and thought all had turned…. But spurt is exactly what it was. Like many of you, I certainly hope this increase continues. We find companies are shopping their requirements harder for lower cost while keeping the quality the same or even better. Total Solution Plastic is very proud to day we are alive and healthy. Our shop in Shenzhen is operating at a very healthy level, but even still capacity is available.
Plastic Injection Molds Projects
I have spoken many times before about communications and its significance to achieve a successful and timely project completion date. Customers have experienced time and time again, their Plastic Injection Molds projects not only ship on time, but many time ahead of schedule! Our Proprietary Web Portal has been the solution. No longer are emails lost or change orders misplaced or not followed. Our Portal controls these processes. It is all about the “Total Cost of Acquisition”! No need to change shipping from the planned sea shipment to much more expensive air shipments due to lost time or missed schedules! We deliver on time… in fact we boast quite strongly that WE HAVE NEVER MISSED A T1 DATE!!
I would appreciate your responses to issues you have experienced in procuring of shore tooling. As you well know, “the price is not always the price”.
When does buying injection molds from China make you a good American?
November 19, 2011 by
Injection Molds from China
It‘s all about jobs, and in our case injection mold jobs. We need to supply jobs for the people here in America. So why does going to China for your injection molds help people here in America keep their jobs? Sometimes you have to pick your battles to win the wars. We use a lot of plastic here in America, everything from medical devices to automotive parts. Most of it requires some kind of plastic mold and very often this is an injection mold.
Injection molds are very labor intensive and this is where China has a huge advantage over the United States. Their labor rate is so much lower we cannot even attempt to compete. Anything that is more labor than material is not a level playing field between the United States and China. So let’s not try. Let’s let China do what they do well and then we get to do what we do well. With proper due diligence, let China build the labor intensive injection molds. Based on your annual usage these injection molds can last a long time making the injection mold costs go a long way in the overall cost of the project.
Injection Molds from China – Cost Analysis
Now, when it comes to the molding of the part, that is a different story. This is very much automated which makes it almost impossible for China to be competitive as there is very little labor. So as American companies we can be my most competitive by buying injection molds from China and using our expertise and investment dollars in the plastic injection mold process in our shops. Our core competency would be molding of the plastic. So, while a lot of shops like to be a one stop shop, the reality is you need to decide how to be the most competitive and develop core competencies. In this way you offer competitive pricing, which allows for the growth of your company, which allows for job creation.
As you can see, using China and their labor rates in your business plan can create additional jobs here in the United States. Consider this the next time you have requirements for injection molds.
Be a good American and buy your injection molds from China.
Injection Mold – Making Inventions a Reality
November 18, 2011 by
Plastic Injection Mold idea to a reality
Most everyone has heard or said “you could make a million bucks with that idea.” Or “Yeah that and fifty cents will get you a cup of coffee.” In actuality they both cost more in the “real world”. It is our mission to assist Inventors as well as seasoned designers to help bring their Plastic Injection Mold idea to a reality.
This process takes money, but thanks to foresight to buy into our Injection Mold Partner in Shenzhen China, we are able to offer from 30-50% cost savings over many of our domestic (USA) suppliers. One would ask, how can you do that? Building an Injection Mold is labor intensive. We use the same quality steel as you find here in the USA, and all components that are replaceable are USA supplier standard (DME etc.). The difference is labor cost in China. Our engineers as well as manufacturing folks are highly skilled and can easily be compared to those here in the United States.
Injection Mold Project
Now let’s talk about the security of your Intellectual Property. Each person here at Total Solution Plastic that touches your Injection Mold project has signed a legal nondisclosure form. Each of our associates in China that will be in contact with your Injection Mold project have signed a legal nondisclosure form. In other words, we have taken as much precaution to protect your injection mold idea as possible. I do want to add, in most cases our shop does not even know the application of your product… which once again adds to your protection. We build many “sensitive” products in our shop each year from medical to automotive…. I do not want to “ever” guarantee, nor would anyone else, that your Intellectual Product is totally secure, but certainly, we are more than diligent to protect you, and do not foresee any issue with this. We have been audited by many very large OEMs and haven’t had any issue at all with security measures due to the processes we have in place.
After your part is produced to your satisfied to your satisfaction we bring your Injection Mold back to the United States and assist you in finding a supplier nearest you to run the Injection Mold and supply you parts. This allows you to maximize your profit dollars by reducing your Injection Mold cost. Resale – cost = Profit is what we help you accomplish.
I have worked with Inventors for the past thirty five years at many levels and have seen many potentially great products not brought to market due to the lack of proper capitol. It is a shame, because great ideas is what makes this country grow! Please do not misunderstand me, our Injection Mold is not free; just much less expensive! Sales projections are the most important information in any new product development. Sales projections drive the production cost as well as start-up and tooling cost that must be rolled into the price which will determine your sales price. By holding down your tooling (Injection Mold) price; that gives you more dollars to spend on your marketing! We want to see you successful! We want to see you selling many of your ideas, so you will return to us with your next Injection Mold project. Many of our customers have been with Total Solution Plastic since we opened our doors! Khey understand our honesty and integrity in the market place and feel we are the best cost, quality and delivery solution for their new products. Please review our website at www.totalsolutionplastic.com and give us a call so that we may help you bring your ideas to reality!
Communications and Purchasing of Injection Molds
November 17, 2011 by
Purchasing Injection Molds
Whether you are purchasing an injection mold from the tool shop down the street or half the way across the world, communications is one of the most important ingredient in a successful program.
Injection Molds Website Portal
Total Solution Plastic as invested in and developed the most sophisticated Web Portal available. No more lost files or email, no more wondering where your mold is in the process, just log on to our secure site (SSL) and view in real-time. You can access your project from any computer anywhere in the word. Check out www.totalsolutionplastic.com.
Purchasing of an Injection Mold
November 16, 2011 by
Injection Mold Management
Whether you are purchasing an injection mold from the tool shop down the street or half the way across the world, communications is one of the most important ingredient in a successful program. Total Solution Plastic has invested in and developed the most sophisticated Web Portal available. No more lost files or email, no more wondering where your mold is in the process, just log on to our secure site (SSL) and view in real-time and in English.
You can access your project from any computer anywhere in the world. Now isn’t that much better than dealing with late night or early morning calls. Or you could jump on an airplane and go see your mold. How expensive is that? Not to mention that while you are there the work is stacking up on your desk.
Injection Mold Accountability
We also provide accountability. Action items are generated and assigned for the whole team to see. This keeps things moving forward. Gantt files are available for your review. In one convenient place we offer you total management of your injection mold. Whether it is to provide status for a meeting, look up an action item of two weeks ago, cover for a sick employee, or just deal with the day to day management of your program, all of the information necessary is there. And if you really want to see the value of this program let’s manage 5 injection mold or ten. It doesn’t matter each project is managed individually with all of the appropriate information at your fingertips.
Communication is the key to a successful project and a quality mold. Done right it also provides for
Increased cost and time savings. Check out our web site at www.totalsolutionplastic.com. We talk about our project management system as well as our company and capabilities. Then give us a call and let us show you how we can save you money with a great injection mold managed with great communication.
Understanding Injection Molds
November 15, 2011 by
Please follow the link below to watch a video that explains the many features of an injection mold.
Injection Mold Making – Eight Phases of a Tool Transfer
November 14, 2011 by
Eight Phases of a Tool Transfer
Article From: MoldMaking Technology, Sherry L. Baranek , John Berg, Marketing Director from MGS Mfrg. Group 2
Posted on: 4/1/2011
Eight Phases of a Tool Transfer
It is big news when an OEM decides to move a substantial number of existing molds from one molding operation (either their own in-house/captive facility or an outsourced molder) to a selected custom molder.
Tool Transfer
Mold transfers—particularly large ones—require upfront planning, communications and investments that yield the goals and expectations of the project. A complete understanding of the OEM’s goals must be in place at the injection molding operation taking responsibility for the change in venue. The information and activities required leave no room for anything but complete cooperation and disclosure from both sides.
The eight phases of a transfer include:
1. Contractual agreement
2. Partnership
3. On-site assessment
4. Schedule
5. Safety stock
6. Equipment purchase/consigned equipment
7. Validation
8. Production molding
A contractual agreement should be established that provides legal commitment from both parties. The contents will protect the interest of all companies involved over the length of the agreement.
A dedicated and empowered team (see Transfer Program Management Team Sidebar, page xx) must be defined upfront based on the requirements of the project. Both companies must be willing to make whatever personnel arrangements are necessary to ensure success—forming a partnership with open lines of communication between the two management groups.
A detailed on-site assessment of the manufacturing operations at the current facility is required to develop a seamless transfer. During this time, the Project Management transfer team works with the current molding operation to thoroughly understand the production functions from order entry to shipment. This is an especially critical step. It is likely to be the only opportunity to capture the wealth of information that, in many cases, has not been properly documented. Molds that have run for years in the same press by the same operators are often taken for granted because they have run, seemingly successfully, for years.
The small shortcuts and down and dirty fix-ups are seldom noted and shared with management; instead, they become tribal knowledge. Only through observation and interrogation by appropriately experienced technicians (toolmakers and process engineers) are the actual production procedures understood and many hidden manufacturing sins revealed.
Based on what was learned from the on-site assessment, a transfer schedule will be developed. This again will be a joint effort as both parties must participate in its success. All parts, molds and associated production equipment will receive a scheduled date to transfer.
The originating production facility will be responsible to build safety stock per the production requirements of the transfer schedule. The amount of stock needed will be determined during the on-site assessment. The idea is to build enough safety stock that will allow for the tools and equipment to be transferred and validated at the destination facility. Typically, a six-week timeframe will work within the transfer schedule. It is likely that additional shifts and/or weekends will be needed to keep the safety stock build schedule on course.
The new molder may need to purchase any non-consigned equipment that may be critical to production of the transfer parts. Consignment equipment typically includes tooling and spares, fixtures, inspection gauges and all other product specific equipment. The new molder usually accepts standard maintenance responsibility on these items. Major tooling refurbishments will need to be quoted and submitted for approval.
The goal of validation is to gain customer approval on each part to be produced at the new molding facility. A process based on similarity to the existing manufacturing process and golden samples is typically initiated. Flexibility in this process must remain, as individual companies may require product specific production controls.
Upon validation approval, the new molder’s long-term production staff will manage and produce the products within the constraints of the contractual agreement per the projected volumes for each part in the transfer package.
