Mold Builder

Mold Builder in America

The American Mold Builders Association, in conjunction with the group’s 30th anniversary in 2003, has announced the establishment of a new Mold Builder of the Year Award. This first annual event offers AMBA members the opportunity to nominate one of their peers or themselves for this prestigious honor.

The Mold Builder of the Year Award was created to recognize outstanding contributions made by an AMBA member. The recipient of the award will be an outstanding business leader, dedicated to the industry, and an active member of AMBA.

Mold builders tend to be ‘behind-the-scenes’ guys, so we want them to step forward and showcase the best of the best of the industry,” says Scott Harris, president of Harris Precision Mold in Tempe, Arizona, and president of the AMBA.

Criteria for eligible nominees can be found on the AMBA website. Nominations can be submitted by filling out the nomination form there, or from a mass e-mailing that is scheduled to be sent to all members of the organization. Three independent judges from the industry will review the nominations. The deadline for submitting nominations is January 15, 2003.

The Mold Builder of the Year will be honored at the upcoming AMBA Annual Convention in Amelia Island, Florida, March 18–23, 2003.

plastic mold builders
plastic mold builders

The American Plastic Mold Builders Association is the largest mold building trade organization in North America, with more than 400 members and 12 chapters in 35 states.go to one of China Mold builders by click https://www.hao-mold.com/

Advantages of hao-mold.com

Alon Zelzion has been named as the new vice president of marketing at hao-mold.com. He brings 23 years of marketing, business development and management experience to this major developer of CAD/CAM solutions for the tooling industry.

“Zelzion is an accomplished executive with extensive marketing and business experience,” says Nitzan Sapir, president and CEO of Cimatron. “His entrepreneurial spirit, his experience in international business, and his background in software in a number of industries make him an excellent choice to lead new initiatives in corporate marketing and business development.”

Through its data-to-steel product philosophy, Cimatron is committed to providing mold, tool, and die makers with comprehensive, cost-effective solutions that streamline manufacturing cycles, enable collaboration with outside vendors, and ultimately shorten product delivery time.

Strengths of Polish Plastics Industry

According to the latest review of the plastics processing industry in Poland issued by the Applied Market Information Group (AMI), there are signs that growth in that industry may have peaked. Although there have been substantial increases in polymer consumption in Poland recently—the market is expected to have advanced by nearly half a million tonnes in the five-year period 1997-2002—rates of expansion have slowed notably in the past two years. Polish polymer demand is expected to be up no more than 5% in 2002, compared with 8% growth in 2001 and 11% in 2000.

The AMI report characterizes the Polish plastics processing industry as highly fragmented, with a large number of small, family businesses. AMI’s report details over 1,300 of the most important companies. The processes carried out by these companies are illustrated in the pie chart shown above. (Some companies carry out more than one process, so there is some double counting.)

The largest number of companies are involved in injection moulding. There has been considerable growth in this sector as foreign-owned component suppliers moved in as suppliers to automotive and appliance manufacturers.

While injection moulders are the most numerous, the largest sector of the plastics processing industry in Poland in terms of volume is film extrusion. Again, there has been increasing investment by foreign companies.

Nearly all other sectors of plastics processing have seen considerable involvement from Western-owned groups. However, while Poland has been very successful in attracting high levels of foreign direct investment (FDI)— some $7.14 billion for 2001—approximately 70% of processors identified by AMI are privately owned.

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Thermoset Compression Molding

Thermoset Compression Molding

Thermoset compression molding is historically the most common method of molding thermosetting resins; it is certainly the oldest, and many existing molds are of this type. Compression molds typically have a single cavity, although dual-cavity and even multi-cavity molds are possible.

A preheated preform is placed in the open mold

As the mold closes, the preform is compressed and starts to flow

The heated mold is held shut until the resin cures …

… then the mold is opened and the finished part ejected.

What characterizes compression molding is the method of charging the mold with resin: the plastic resin is placed directly in the bottom cavity of the open, heated mold, and then the top half of the mold is closed down on the resin under tremendous pressure, causing the resin to flow throughout the cavity until it completely fills the now-closed mold and assumes the shape of the finished part.

COMPRESSION MOLDING WORKS

The compression action itself generates heat, and in conjunction with the heat of the plastic mold, raises the temperature of the resin to the point where a chemical reaction called “crosslinking” takes place. It is this crosslinking that gives thermoset molded parts their characteristic strength, hardness and rigidity.

The heated mold is held closed for sufficient time to ensure that the crosslinking reaction is complete; this is called “curing,” and the length of time required for the cure cycle is almost entirely dependent on the wall thickness of the finished part. The thicker the part at its maximum cross section, the longer the curing time required for a given mold temperature.

Thermoset molding resins typically come in a powder or granulated form. Metering the correct amount of resin (called the “shot”) into the mold is accomplished in one of two ways. One is called “preforming” and the other is called “direct charging.”

PREFORMING
In preforming, the exact amount of raw resin required to completely fill the mold (plus a small excess percentage to allow for squeeze-out) is compressed into uniform “pills” — sometimes called “hockey pucks” in industry slang, because that’s what the larger ones look like. These preformed “pills” of resin are produced in batches prior to molding using machines called, appropriately enough, preformers. Preforms are made in various sizes, depending on the size of the mold.

PREHEATING
Just before use, these preformed pills are warmed up in a preheater — which is essentially an industrial-strength microwave oven — which softens the pill into a pliable, dough-like consistency so that the resin will flow more easily under compression. In the molding process, one of these preformed, preheated pills of resin is placed in the bottom cavity of the mold, and the mold is closed, compressing the softened resin into the shape of the mold. (Exceptions to preheating include Bulk Molding Compound (BMC) materials, which are typically formed in logs or used in bulk and are normally molded cold.)

DIRECT CHARGING
Direct charging is used in situations where the mold cavity is too small, too shallow, or too convoluted, to conveniently accept a preform. In these cases, a measured scoop of cold resin is distributed directly into the open mold cavity.

INSERTS
Metal inserts — electrical contacts, female threaded holes, male threaded studs, bushings, and the like — can be placed in the mold cavities, using holes or locator pins, prior to molding. Under compression, the plastic resin flows around these inserts, molding them into the finished piece. Even though thermoset plastics are machinable to a degree, the judicious use of molded-in metal inserts can often eliminate costly secondary operations and add value to the finished parts.

Metal inserts can be molded into the bottom surface, the top surface, or both surfaces of the finished parts. They can even extend completely through the piece. In cases where the inserts are especially small, or cannot be properly supported within the mold, they can be epoxied in as a secondary operation.

THERMOSET COMPRESSION MOLDING:
ADVANTAGES and DISADVANTAGES

In general, thermoset compression molding is well suited for larger pieces of relatively simple design with large, well-anchored inserts. A properly designed and well maintained compression mold will produce very little scrap, and through the use of preheated preforms, total cycle times can rival those of injection molding, plastic molding company

On the PLUS side …

  • Less expensive molds. Compression molds are generally less expensive than other types, both in initial cost and in maintenance.
  • Tighter tolerances, made possible by relatively small shrinkage. Because of the way direct compression packs the preheated preform into the mold, the result is a denser piece that tends to cure solid to the exact dimensions of the mold cavity, without “relaxing back” to create shrinkage. (Exception: dimensions across the parting line are harder to control.)
  • Less scrap can lower material costs.
  • Low-volume jobs are more economical, due to the simplier process and reduced start-up times. Compression jobs can be cycled in and out of the workflow more quickly, and on shorter notice.

On the MINUS side …

  • Heavier flash than other methods is possible. Deflashing is a secondary operation that may add to both labor costs and scrap loss.
  • Labor costs vs. cure time trade-offs. Labor costs can be reduced by using BMC materials and other cold molding techniques which forego preheated preforms, but the cure cycles will be longer.
  • Parting line thicknesses can vary making dimensions across the parting line more difficult to control tightly.
  • Metal inserts may be flashed, leading to more labor-intensive deflashing and clean up.
  • Deep, small diameter holes are difficult to mold reliably; in general, cored holes should be limited to 2.5 times their diameter in depth.

Typical Applications

Thermoset compression moldings are all around you. From the knobs on your stove to the electrical boxes in a jumbo jet — if it’s plastic, hard, rigid, heat-scratch-and-chemical-resistant, an electrical insulator, and it’s got molded-in metal inserts, and it’s black (or shades of reddish brown) — chances are it’s a thermoset molded product.

  • Aerospace — an aircraft terminal housing is just one example where thermoset moldings provide the excellent dielectric properties, lightweight rigidity, and dimensional stability required by precision in-flight systems.
  • Household Appliances — a blower fan blade for a residential clothes dryer illustrates the ability of thermoset compression molded products to meet critical density and dimensional stability requirements.
  • Industrial Machinery — an adjustment wheel for an industrial milling machine displays the rugged workhorse qualities of a typical thermoset compression molding.

Other Molding Methods

Compare with Thermoset Transfer Molding, which is similar to compression molding, but with important differences.

Compare also with Thermoset Injection Molding, a familiar process in thermoplastics, now equally applicable to many thermoset materials.

Thinwall Injection Mould

Thinwall Injection Mould

In order to produce the new parts any sorts of machine, Moulding process is utilized. Moulding process helps to generate the strong and worthy parts easily and instantly. Bi-color injection mold is preferred by many companies, as it will produce the component in two colors. The components, which produced in this model, will be more attractive. Mostly, toys, dolls, toothbrushes, buttons, switches will be prepared using this model. Apart from Bi-color injection mold, BMC molding and thin wall Injection molding products also have more fame among the people. The important and specialty of this process exist in the selecting the color combination. If the color combination matches well, the certain product will reach the customers in large amount and its market ranges increases a lot.

BMC injection moldings products will be more strong and stable. Thus, the plastic mold components required for the transportation, sports, electrical related works are prepared using this moulding process. The materials prepared using the BMC molding process will be very flexible and they can be extended easily. BMC objects will be great in withstanding the heat for long time. Thus, electrical appliances are mostly prepared using this model, in order to get the heat withstanding capacity. BMC material will remain constant upto 130 degree of heat. Also, BMC material will not be wasted soon and they can remain for long period without any damage, if it is handled carefully. During BMC molding, the essential materials should be mixed in the perfect ratio and suitable temperature should be applied. Then only it is possible to procure the stretchy and reliable BMC materials.plastic mold

Thinwall Injection Mould to make Thinwall Injection Mold molding parts, the process is not that much easy process as like other molding process. In order to generate the thin products, this molding process is utilized. Using this process, large number of components can be prepared in a short period. Mostly to produce the electronic components like mobile, laptop and computer parts, this molding process will be used.

As Chinese people prefer the plastic utensils in large amount, there is large demand for the plastic utensils in china. The thin plastic utensils are prepared using the Thinwall Injection Molding process. High speed plastic molding machines, thin wall moulds are very essential to carry out this process. Along with these parts Robot system also should be available to execute this process successfully. Robot system performs the work of lifting and placing the molded material carefully in one place.

Chinese Molding companies are very careful in producing the products using the moulding process. They incorporate the high quality materials during the moulding process to procure the quality rich products. Thus, the molding products created by the Chinese companies are very reliable and worthy. Not only they concentrate in materials to be incorporated but also they will focus on mold machine, mold design, cooling system and so on. They will pay attention on each and every thing. These reasons play an important role in delivering the Chinese molding products in market in large amount. Since, molding process is performed with help of machines; the shape of the products will be accurate.