Air Care Products

Injection Moulding Tool Design Services

Air Care Products is an established injection moulding tool design company, established in 1970, producing products for many diverse industries such as automotive, medical, air purification, gardening, and water treatment.

Across 50 years, we have worked in many different fields of injection moulding, giving us an extensive range of knowledge when designing different types of products. The design process of a tool starts with the client’s idea, our team will then oversee the development of a product to ensure it’s made in the most efficient and practical way possible.

Call us on 01206 564443

Key Factors to Consider in Creating High-Quality Mould Designs

Introduction to Injection Moulding Tool Design

Injection moulding is a widely used manufacturing process for producing plastic parts in large volumes. The key to successful injection moulding lies in the design of the mould itself. A high-quality mould design not only ensures the production of accurate and consistent parts but also contributes to the overall efficiency and profitability of the manufacturing process. We understand the essential factors to consider when creating injection moulding tool designs.

Importance of High-Quality Mould Designs in Injection Molding

The mould design quality directly impacts the final product’s quality. A well-designed mould ensures that the plastic material flows smoothly, fills the cavities evenly, and solidifies without defects. It also helps prevent issues like warping, shrinkage, and poor surface finish. By investing time and effort into creating high-quality mould designs, manufacturers can minimise scrap rates, reduce production costs, and improve overall customer satisfaction.

Factors to Consider in Injection Moulding Tool Design

Designing a mould for injection moulding requires careful consideration of several key factors. These factors significantly affect the overall performance and cost-effectiveness of the manufacturing process. Here are some important considerations we keep in mind:

1. Material Selection: Choosing a suitable material for the mould is crucial. Factors such as temperature resistance, durability, and compatibility with the injected material need to be considered. Common materials for mould-making include steel, aluminium, and various alloys.

2. Part Design: Proper part design is essential for efficient injection moulding. Factors like wall thickness, draft angles, and gate location ensure easy flow of the material and easy ejection of the part from the mould.

3. Mould Flow Analysis: Conducting a mould flow analysis helps identify potential issues before the mould is manufactured. It simulates the flow of molten plastic within the mould, allowing designers to optimise the design for better filling, cooling, and part quality.

4. Parting Line: The parting line is the line where the two halves of the mould separate. It is essential to design the parting line to minimise cosmetic defects and ensure proper alignment of the mould halves.

5. Gate Design: The gate is the entry point for the molten plastic into the mould cavity. The gate design affects the filling pattern, part quality, and overall cycle time. Common gate types include sprue gate, edge gate, and hot runner gate.

6. Venting: Proper venting allows the escape of air and gases from the mould cavity during the injection process. Insufficient venting can lead to defects like burning, voids, or gas traps. Designing the mould with adequate venting channels is crucial to ensure high-quality parts.
Injection Moulding Design Guidelines
To achieve optimal mould designs, it is essential to follow certain design guidelines specific to injection moulding. These guidelines are based on industry best practices and help maximise part quality and process efficiency. Here are some of the key guidelines we consider.

7. Uniform Wall Thickness: Maintaining a uniform wall thickness throughout the part helps ensure consistent filling and cooling, minimising the risk of defects like sink marks and warping.

8. Draft Angles: Incorporating draft angles on vertical surfaces allows for easy ejection of the part from the mould. Draft angles also help prevent damage to the mould and reduce the chance of cosmetic defects.

9. Ribs and Bosses: Ribs and bosses are structural features that provide strength and rigidity to the part. Designing ribs and bosses with proper thickness ratios and radii is important to avoid sink marks and flow restrictions.

Making an Injection Mould

Creating an injection mould involves a series of carefully planned steps. While the process may vary depending on the complexity of the mould design, the following steps provide a general overview of the mould-making process:

10. Part Design: The process begins by designing the part to be manufactured and considering factors like part geometry, function, and material requirements.

11. Mould Design: Based on the part design, a mould design needs to incorporate features like cavities, cores, ejection systems, cooling channels, and gating.

12. Mould Manufacturing: Once the mould design is finalised, we can proceed with manufacturing the mould using appropriate materials and machining techniques.

13. Mould Testing and Refinement: We test the mould by injecting molten plastic and producing sample parts. Analyse the samples for any defects or performance issues and make necessary adjustments to the mould design if required.

14. Production and Maintenance: Once the mould is approved for production, we start to manufacture parts on a larger scale. Regular maintenance and cleaning of the mould are essential to ensure its longevity and performance.

Common Challenges in Injection Moulding Tool Design and How to Overcome Them

While designing injection moulding tools, it is possible to encounter various challenges that can impact the quality and efficiency of the manufacturing process. Here are some common challenges and strategies to overcome them:

15. Warpage: Warpage is the deformation of the part due to uneven cooling or material shrinkage. To minimise warpage, we optimise cooling channels, adjust part geometry, and use appropriate materials with lower shrinkage rates.

16. Sink Marks: Sink marks are depressions on the part’s surface caused by uneven cooling or insufficient packing of the material. If necessary, we can modify wall thickness, adjust gate location, and optimise packing pressure and time to prevent sink marks.

17. Flash: Flash is excess material that escapes from the mould cavity and forms thin fins along the parting line. Proper mould clamping, gate design, and adequate venting can help prevent flash formation.

Best Practices for Creating High-Quality Mould Designs

To ensure the creation of high-quality mould designs, it is crucial to follow some best practices. Incorporating these practices into the design process can improve part quality, reduce cycle times, and increase overall efficiency. Here are some best practices to consider:

18. Collaboration: Collaboration is essential between the designers, mould makers, and our injection moulding experts to leverage their expertise and achieve optimal mould designs.

19. Continuous Improvement: We embrace a culture of continuous improvement by regularly assessing and refining the mould design process based on feedback and lessons learned.

20. Use of Advanced Software: We utilise advanced computer-aided design (CAD) software and mould flow analysis tools to optimise mould designs and predict potential issues.

Injection Moulding Part Design: Optimising for Efficiency and Quality

While mould design plays a crucial role in injection moulding, the part’s design also impacts the manufacturing process’s efficiency and quality. When designing parts for injection moulding, it is important to consider factors like material selection, part geometry, and functional requirements. Optimising part design can improve fill times, reduce cycle times, and enhance part quality.

Tools and Resources for Injection Moulding Tool Design

Several tools and resources are available to assist designers in creating high-quality mould designs. These tools range from CAD software and mould flow analysis tools to online resources and industry guidelines. By utilising these resources, designers can streamline their design process, enhance their understanding of injection moulding principles, and stay up-to-date with the latest industry trends.

Conclusion: Injection Moulding Tool Design creates superior results

Injection moulding tool design is a critical aspect of the injection moulding process. A high-quality mould design directly impacts the manufacturing process’s quality, efficiency, and cost-effectiveness. By considering the key factors, following design guidelines, and incorporating best practices, we create injection moulding tool designs that result in superior product quality, reduced production costs, and increased customer satisfaction.

Are you looking for an injection moulding company with comprehensive resources and expertise, including design, industry insights, and advanced tools?

Call us on 01206 564443.