How to save plastic mold cost?

For leave the mold in China production:
1, Specify the mold life for mold steel selection
2, Specify the surface finishing
3, Specify the color
4, Specify the resn used for molding, if you do not know what kind of resin you neeed, you can specify the function of your product.

Based on above, we will choose the most cost saving solution, also you can review our prototype page on our blogger

Detail 2d and 3D mold drawing before mold making

Our engineering includes:


1. Pro/ENGINEER (3D product design)

2. SolidWorks (3D product design)

3. Unigraphics NX(3D mold design)

4. AutoCAD (2D details)

5. Mold Flow (Molding analysis before mold Start)

6. Plastic mould making and Plastic molding experience

What kind of texture you can do?

Mold-Tech, Yick Sang etc, or you can offer the texture samples for reference.

What kind of hot runner system you used?

MOULD MASTER, Master TIP, HUSKY, HASCO, DME, YUDO, INCOE, HRS etc

What kind resin used for plastic molding?

We specializing in thermoplastic molding with all type of thermoplastic including, ABS, Polystyrene, Polypropylene, Polyethylene, Polystyrene, Acrylic,, Acetal, Nylon, PBT, ASA, PVC, CPVC, UPVC, PC, PC/ABS, PPS, PPA, Elastomers, PPO, etc

Can you do mold flow analysis and warp analysis?

Yes, Seasky make the mold flow and warp analysis.

Can you do product design?

We can do product design, also we have US partner to support product design also.

If is not complex, we can finish in China directly. If it is complex and need lots of detail communication for the product design, then we will let our US partner to support.

What kind of steel we can use for MUD mold insert?

We use H13, P20, 2344, S7, S136 etc steel for MUD mold insert, just like the common plastic mold.

What kind of steel we used for MUD mold base?

We use P20, H13 etc for MUD mold base, also we can consider to use the steel what customer suggest.

Is big MUD mold save cost, please?

Big MUD mold request have more diffcult to control the precise area such as slot area and the other locking area. Normall we had better to control the mold size smaller than 400mm x 400mm.

PBT molding

PBT
Generic Class
PBT (Polybutylene Terephthalates)

Typical Applications
Household appliances (food processor blades, vacuum cleaner parts, fans, hair dryer housings, coffee makers, etc.), electronics (switches, motor housings, fuse cases, key caps for computer keyboards, connectors, fiber optic buffer tubing, etc.), automotive (grilles, body panels, wheel covers, and components for doors and windows, etc.)

Injection Molding Processing Conditions
　

Drying
This material is sensitive to hydrolysis at high temperatures. It is therefore important to dry the material prior to molding. Suggested drying conditions (in air) are 120 C (248 F) for 6 - 8 hours (or 150 C (300 F) for 2 - 4 hours). Moisture levels must be below 0.03%. When using a desiccant dryer, drying at 120 C (248 F) for 2.5 hours is recommended.

Melt Temperature
220 - 280 C (428 - 536 F); aim: 250 C (482 F)

Mold Temperature
40 - 60 C (104 - 140 F) for unreinforced grades. For other grades, a wide range of temperatures can be used, depending on the grade (15 - 80 C / 59 - 176 F). Cooling channels should be properly designed to minimize part warpage. The heat removal must be fast and uniform. Cooling channels of 12 mm diameter are recommended.

Resin Injection Pressure
Moderate (up to maximum of 1500 bar / 21750 psi).

Injection Speed
Fastest possible speeds should be used (due to fast solidification of PBTs)


Runners and Gates
Full round runners are recommended to impart maximum pressure transmission (rule of thumb: runner diameter = part thickness + 1.5 mm). A wide variety of gates may be used. Hot runners may also be used, taking care to avoid drool and material degradation. Gate diameters or depths should preferably be between 0.8 - 1.0 times the part thickness. When using submarine gates, the minimum recommended diameter is 0.75 mm.

Chemical and Physical Properties
PBT is one of the toughest engineering thermoplastics. It is a semicrystalline resin and has excellent chemical resistance, mechanical strength, electrical properties (high dielectric strength and insulation resistance), and heat resistance, all of which are stable over a broad range of environmental conditions. It has very low moisture absorption.

PBT, which is a polyester, is produced by the polycondensation reaction of dimethyl terephthalate an butanediol.

Tensile strength ranges from 50 MPa (7,250 psi) for unfilled grades to 170 MPa (24,650 psi) for glass reinforced grades. High levels of glass fillers make the material more brittle. Crystallization is rapid and this could cause warpage due to non-uniform cooling. In the case of glass filled grades, shrinkage is reduced in the flow direction, but in the cross-flow direction it may be equal to that of the base resin. Shrinkage is of the order of 0.015 - 0.028 mm/mm (1.5 -2.8%). A 30% glass-filled resin has a shrinkage range of 0.3 - 1.6%. The melting point (approximately 225 C / 437 F) and heat distortion temperatures are lower than that of PET. The Vicat softening point is approximately 170 C (338 F). The glass transition temperature ranges from 22 - 43 C (71 - 109 F).

The melt viscosity is fairly low and due to fast crystallization rates, cycle times are typically low.

Major Manufacturers
BASF (Ultradur), Ticona (Celanex), GE Plastics (Lomod, Valox), Bayer (Pocan), Huls (Vestoduv), Mitsubishi Engineering Plastics (Novadur), Teijin Chemicals.

PA 66 molding

PA 66
Generic Class
PA 66 (Polyamide 66, or Nylon 66, or poly (hexamethylene adipamide))

Applications
Competes with PA 6 for most applications. PA 66 is heavily used in the automotive industry, appliance housings, and generally where impact resistance and strength are required.

Injection Molding Processing conditions
　

Drying
Drying is not required if the material is sealed prior to molding; however, if the containers are left open, drying in a hot air oven at 85 C (185 F) is recommended. If the moisture content is > 0.2%, vacuum drying at 105 C (220 F) for 12 hours is recommended.

Melt Temperature
260 - 290 C (500 - 554 F); 275 - 280 C (527 - 536 F) for glass filled grades; melt temperatures above 300 C (572 F) should be avoided

Mold Temperature
80 C (176 F) suggested. Mold temperature affects crystallinity level which in turn affects physical properties. In the case of thin walled parts, crystallinity changes with time if mold temperatures of less than 40 C (104 F) are used. In such cases, annealing may be needed to retain dimensional stability.

Resin Injection Pressure
Generally between 750 - 1,250 bar (~11,000 - 18,000 psi), depends on material and product design

Injection Speed
High (slightly lower for reinforced grades)


Runners and Gates
The gate location is important because of very fast freeze-off times. Any type of gate may be used; the aperture should not be less than half the thickness of the part. When hot runners are used, the size of the gates can be smaller than when cold runners are used, because premature freeze-off is prevented. When using submarine gates, the minimum diameter of the gate should be 0.75 mm.

Chemical and physical properties
PA 66 homopolymer is produced by the polymerization of hexamethylene diamine and adipic acid (a dibasic acid). Among commercially available polyamides, PA 66 has one of the highest melting points. It is a semicrystalline-crystalline material. The resins have strength and stiffness which is retained at elevated temperatures. It does absorb moisture after molding, but the retention is not as much as in the case of PA 6. Moisture absorption depends on the composition of the material, wall thickness, and environmental conditions. Dimensional stability and properties are all affected by the amount of moisture absorption which must be taken into account for product design.

Various modifiers are added to improve mechanical properties; glass is one of the most commonly used filler. Addition of elastomers such as EPDM or SBR improves impact resistance.

The viscosity is low and therefore, it flows easily (but not as easily as PA 6). This allows molding of thin components. The viscosity is very sensitive to temperature. Shrinkage is of the order of 0.01 - 0.02 mm/mm (1 - 2%). Addition of reinforcing glass fibers reduces the shrinkage to 0.2 - 1%. Differential shrinkage in the flow and cross-flow directions is quite high. Mineral fillers yield more isotropic moldings. PA 66 is resistant to most solvents but not to strong acids or oxidizing agents.

Major Manufacturers
BASF (Ultramid A), DuPont (Minlon - mineral reinforced grades; Zytel), Monsanto (Vydyne), DSM (Akulon).

PA6 molding

PA 6
Generic Class
PA 6 (Polyamide 6, or Nylon 6, or Polycaprolactam)

Applications
Used in many structural applications because of its good mechanical strength and rigidity. It is used in bearings because of its good wear resistance.

Injection Molding processing conditions
　

　

Drying
Since PA 6 absorbs moisture readily, care should be taken to ensure its dryness prior to molding. If the material is supplied in watertight packaging, the containers should be kept closed. If the moisture content is >0.2%, drying in a hot air oven at 80 C (176 F) for 16 hours is recommended. If the material has been exposed to air for more than 8 hours, vacuum drying at 105 C (221 F) for more than 8 hours is recommended.

Melt Temperature
230 - 280 C (446 - 536 F); 250 - 300 C (482 - 572 F) for reinforced grades

Mold Temperature
80 - 90 C (176 - 194 F). Mold temperature significantly influences the crystallinity level which in turn affects the mechanical properties. For structural parts, a high degree of crystallization is required and mold temperatures of 80 - 90 C (176 - 194 F) are recommended. High mold temperatures are also recommended for thin-wall parts with long flow lengths. Increasing the mold temperature increases the strength and hardness, but the toughness is decreased. When the wall thickness is greater than 3 mm, a cold mold is recommended (20 - 40 C / 68 - 104 F), which leads to a higher and more uniform degree of crystallinity. Glass reinforced resins are always processed at mold temperatures greater than 80 C (176 F).

Resin Injection Pressure
Generally between 750 - 1,250 bar (~11,000 - 18,000 psi) (depends on material and product design)

Injection Speed
High (slightly lower for reinforced grades)


Runners and Gates
The gate location is important because of very fast freeze-off times. Any type of gate may be used; the aperture should not be less than half the thickness of the part. When hot runners are used, the size of the gates can be smaller than when cold runners are used, because premature freeze-off is prevented. When using submarine gates, the minimum diameter of the gate should be 0.75 mm.

Chemical and Physical Properties
The molecular structure of polyamides consist of amide (CONH) groups joined by linear aliphatic sections (based on methylene groups). The toughness, rigidity, crystallinity, and thermal resistance of polyamide resins are due to the strong interchain attraction caused by the polarity of the amide groups. The CONH groups also cause a lot of moisture absorption.

Nylon 6 is produced by polymerization of caprolactam. The chemical and physical properties are similar to that of PA 66. However, its melting point is lower than PA 66 and it has a wider processing temperature range. Its impact strength and solvent resistance are better than PA 66, but its moisture absorption is higher. Many properties are affected by moisture absorption, which must be taken into account when designing with this resin. Various modifiers are added to improve mechanical properties; glass is one of the most commonly used fillers. Addition of elastomers such as EPDM or SBR improves impact resistance.

For unfilled grades, shrinkage is of the order of .01 - .015 mm/mm (1 - 1.5%). Addition of glass fibers reduce the shrinkage to as low as 0.3% in the flow direction (but could be as high as 1% in the cross-flow direction). The post-molding shrinkage is affected mainly by the crystallinity level and moisture absorption. The actual shrinkage is a function of part design, wall thickness, and processing conditions.

Major Manufacturers
BASF (Ultramid B), DuPont (Zytel), DSM (Akulon)

ABS molding

ABS
Generic Class
ABS (Acrylonitrile-Butadiene-Styrene)

Typical Applications
Automotive (instrument and interior trim panels, glove compartment doors, wheel covers, mirror housings, etc.), refrigerators, small appliance housings and power tools applications (hair dryers, blenders, food processors, lawnmowers, etc.), telephone housings, typewriter housings, typewriter keys, and recreational vehicles such as golf carts and jet skis.

Injection Molding Processing Conditions
　

Drying
ABS resins are hygroscopic and drying is required prior to processing. Suggested drying conditions are 80 - 90 C (176 - 195 F) for a minimum of 2 hours. Resin moisture content should be less than 0.1%

Melt Temperature
200 - 280 C (392 - 536 F); Aim: 230 C (446 F)

Mold Temperature
25 - 80 C (77 - 176 F). (Mold temperatures control the gloss properties; lower mold temperatures produce lower gloss levels)

Resin Injection Pressure
500 - 1,000 bar (7,250 - 14,500 psi)

Injection Speed
Moderate - high


Chemical and Physical Properties
ABS is produced by a combination of three monomers: acrylonitrile, butadiene, and styrene. Each of the monomers impart different properties: hardness, chemical and heat resistance from acrylonitrile; processibility, gloss, and strength from styrene; and toughness and impact resistance from butadiene. Morphologically, ABS is an amorphous resin.

The polymerization of the three monomers produces a terpolymer which has two phases: a continuous phase of styrene-acrylonitrile (SAN) and a dispersed phase of polybutadiene rubber. The properties of ABS are affected by the ratios of the monomers and molecular structure of the two phases. This allows a good deal of flexibility in product design and consequently, there are hundreds of grades available in the market. Commercially available grades offer different characteristics such as medium to high impact, low to high surface gloss, and high heat distortion.

ABS offers superior processibility, appearance, low creep and excellent dimensional stability, and high impact strength.

Major Manufacturers
Dow Chemical (Magnum grades), GE Plastics (Cycolac), Bayer (Lustran), BASF (Terluran), Chi Mei (Polylac), LG Chemical (Lupos), Cheil Synthesis.

Mould General Check List


Mould General Check List

Individual Plates


1 Pry bar slots are located in a position which will insure mould separation without damaging components?
2 Eye bolt holes are installed according to engineering prints to ensure safety of handling and are properly thread?
3 Tapped holes have been installed to attach the mould parting line lathes and prevent opening?
4 Plates have been properly machined to carry all vents to atmosphere?
5 Mould plates have been deburred and chamfered?
6 All wires are properly channeled and secure according to engineering prints?
7 Mould includes all components specified on Bill of Material?
8 Mould with lift bar attached hangs level within .125"?


Moulding surface


1 Runners are are radiused and polished to SEASKY specifications.
2 Runners are to print specification.
3 Gates are to print specification.
4 Cavity inserts have been polished as specified.
5 Cavity blocks have been deburred and polished as specified.
6 Core inserts have been deburred and polished as specified.
7 Core blocks have been deburred and polished as specified.
8 Do parting line properly seal off?
9 All engraving is as specified on mould drawings.


Ejector Side Assembly


1 Pin retainer plate and ejector plate are deburred and chamfered to SEASKY standards
2 Ejector plate slides freely on guided ejector
3 Ejector pins fit properly in their holes and spin freely from parting line.
4 Ejector housing has been deburred and chamfered.
5 Machine knockout holes are tapped and arechamfered to SEASKY standards
6 Ejector pins are keyed for non-rotation and identified for location according print specification.
7 Guided ejector bushing press fit retainer plate.
8 Guided ejector bushing slip fit into ejector plate.


General


1 Ejector pins are not chipped or appear to have excessive clearance in their holes.
2 Leader Pins enter bushings before core enters cavity
4 All "in" and "out" lines are labeled to print
5 Mould have been tested with pressurized water and has no leaks
6 Brass pipe plaugs used per Bill of material ( no steel)
7 Labels are instaled on mould base per print specification.

EDM Surface, Relations between surface roughness and draft angle

Relations between surface roughness and draft angle
Surface roughness (EDM surface) Draft angle
AGIE VDI Carmilles Ra (um) PA PC ABS
　 　 　 　 　 　 　
10 42 39 11 4 5.5 4.5
9 39 36 7 3 4.5 3.5
8 36 33 5 2 3.5 2.5
　 33 30 3.15 1.5 2 2
7 30 27 2.24 1 2 1.5
6 27 24 1.6 0.5 1.5 1
5 21 18 0.8 0.5 1 0.5
ESS (Ericsson Surface Standard) is roughly VDI*5

What you should do on plastic mold inquiry

If you need to send plastic mold or plastic molded parts inquiry, you should prepare following information,
1,to leave the mold in China or you need to import the mold to produce as this will make the mold standard is not the same, also affect the mold price.
2,to be better specify the resin for plastic parts
3,specify the mold life you need, the question is like how many parts you need to purchase each year.

For export mold, request more information, normally professtional will offer details specification
4, mold is DME, HASCO OR DAIDO standard.
5, steel for core and cavity
6, surface finishing
7, sampling quantities and so on.............

Repid Prototype Tooling (RT)

RT is a kind or rapid manufacture technology, which derives from the development of RP technology and new material. At present, abroad using material is silicon rubber, which will be used to carry out the fast irrigating for the template. ZK series vacuum molding system operates easily, vacuumizing fast and manufacturing cost is low. Because it can produce the characteristic high precision and a few diversification products, it can compare beauty with molding original part completely. And it is more reliable, perfect than traditional samples. It also reduces the corporation’s developing cycle of new product.

Duplicate mould material adopts the import PU material which can reproduce diversification products, such as plastic n, high temperature resistance prototype, transparent prototype soft pastern prototype etc. The characteristics of these products are similar with the ABS/PP/PC/PMMA, and it even can mix color, spray paint, plate on the prototype to great satisfy the requirements of clients.

CNC Prototype

Many sets of CNC machining centers to ensure delivery the model sample speediness:
Characteristic:
Low cost
Good intensity and toughness
High precision
The range of material is wide and it can produce large size products
CNC machining materials
ABS: import, homemade, transparent high temperature resistance etc
PC, PP, PUC, PA, BT, POM, PMMA etc
Copper, aluminum, stainless steel etc
Bakelite, great plastic , 475 pastern board etc

Prototype SLA

The introduction of SLA laser RP materials
SPR 5000 material: it is a kind of solid material which has the durable, good intensity, good toughness and waterproof performance.
Similar ABS material:
American DSM 14120, which has favorable intensity and toughness, waterproof performance and it ca resistant 50-degree high temperature

Transparent material:
American DSM 11120, which is a kind of SLA material, has the durable and waterproof performance.
High temperature resistance: American DSM 12910, which is a kind of SLA material, has the durable performance and it can resistant 130-degree high temperature