What are the causes of the difficulties in manufacturing injection molds, do you know?
The cavity and core are three-dimensional surfaces, which makes the difficulties in manufacturing injection molds
The cavities and cores directly shape plastic parts’ external and internal shapes, and these complex three-dimensional surfaces are difficult to process, especially the blind holes in the cavities.
If the traditional processing method is used, it requires a high skill level of workers, many auxiliary jigs and clamps, many tools, and a long processing cycle.
High precision and surface quality are required, and a long service life is required, which makes the difficulties in manufacturing injection molds
Currently, the dimensional accuracy of general plastic parts requires IT6-7, surface roughness Ra0.2-0.1μm, and the corresponding injection mold parts require dimensional accuracy of IT5-6 and surface roughness Ra0.1μm or less.
The laser disk recording surface’s roughness should reach the mirror processing level of 0.02-0.01μm. This requires the surface roughness of the mold to reach 0.01μm or less.
Long-life injection mold is necessary to improve efficiency and reduce costs. The current life of the injection mold generally requires more than 1 million times.
Precision injection mold should use a rigid mold frame, increase the thickness of the template, and increase the support column or conical positioning elements to prevent the mold from deformation after pressure. Sometimes, the internal pressure can reach 100MPa.
The ejector is an important factor affecting the deformation and dimensional accuracy of the product, so the best ejector point should be selected to make the mold release evenly in all places.
Most of the high-precision injection mold in the structure of the panel or the whole structure, which requires the mold parts processing accuracy, interchangeability is greatly improved.
Long process and tight manufacturing time make the difficulties in manufacturing injection molds
Most injection molded parts are complete products with other parts, and in many cases, are in other parts that have been completed, eagerly waiting for the injection molded parts supporting the market.
Because of the high requirements for the shape or dimensional accuracy of the products, coupled with the different characteristics of resin materials, mold manufacturing is completed, and repeated mold trials and corrections are required, making the development and delivery time very tight.
Off-site design and off-site manufacturing make injection mold manufacturing difficult.
Mold manufacturing is not the final destination, but the final product design proposed by the user, the mold manufacturer according to the user’s requirements, the design and manufacture of molds, and in most cases, the injection production of products also in other manufacturers.
This causes the situation that the product design, mold design, manufacturing, and production of products are carried out in different places.
Professional division of labor, dynamic combination makes the difficulties in manufacturing injection molds
The mold production batch is small, and generally belongs to the production of a single piece, but the mold needs a lot of standard parts, as large as the mold frame, small to the thimble. These cannot and cannot be completed by only one manufacturer alone, and the manufacturing process is complex, standard equipment and CNC equipment used is extremely uneven.
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