Precision Molds for Complex Part Designs

Injection mold designers must use careful consideration when designing a mold for a complex part design.   Intricate plastic injection molded parts may contain several critical areas that must be carefully designed to meet part specifications.  Parts that contain a very thin wall, for example, would be a critical fill area.  It takes expertise in mold design to fill a part completely without any overfill or under fill while still maintaining the integrity of such a thin critical dimension.

Critical areas should be identified on the part print, and throughout the entire mold design phase.  Sophisticated CAD/CAM software is used to develop a viable tool design given all part design specifications and other exterior design considerations such as the specified material and press size.  With a superior design software program like Unigraphics or SolidWorks, mold designers can develop the entire mold construction phase and test critical areas with computer simulation software.  This advanced quality planning phase is crucial to constructing precision molds to customer specification, and within the established lead time.

The part print will also contain specific information such as the resin used and the surface finish or texture required of the final part.  Any restrictions on knit or parting lines must be identified for proper gating.   It takes an experienced mold designer to implement a successful tool design and construction of a precision mold for injection molded parts with a complex design.

Download our FREE Book on Design Considerations for Different Molds, and contact us today to learn about our discount and rebate programs.  

Michiana Global Mold is an experienced injection mold design and construction company, supplying precision tools to various industries since 1964.  We are an ISO registered mold shop, satisfying the strict requirements of the Automotive industry with high quality complex molds.  Contact us today to speak with one of our knowledgeable engineers for a FREE design consultation.  

Custom Injection Mold Supplier Partners with OEMs

Finding the right injection mold manufacturing company to be a part of your supply chain is a very important decision.  Mold making companies that want to be on a preferred vendor list need to have a competitive edge, something that sets them apart from other mold making shops.   OEMs today need to choose suppliers that can handle large projects, and delivery quality tools on time, regardless of the complexity.  

Michiana Global Mold is an experienced injection mold making facility, supplying high-performing precision molds for over 52 years!  We are experienced with complex designs for molding of critical components in various industries, including precision Automotive components.  

We employ expert mold design engineers, and journeyman mold makers with vast experience in all aspects of custom injection mold design.   Michiana Global Mold utilizes the latest in technologically advanced equipment and software, using CAD/CAM software integrated with our milling centers.   

ISO Registered Mold Making Facility

We are an ISO Registered mold making facility, that will partner with you from the beginning.   Meticulously following a detailed checklist, we are able to identify any critical areas with precision tolerances that may be affected by mold flow or design.  We can even assist with reverse engineering, enhancing your design by alerting you to potential issues prior to cutting steel and working together to obtain the optimum design for your application.  

We are then able to sample your parts and make any necessary final adjustments to your tool, delivering quality parts, on time.  We can construct mold inserts, fully functional molds, mold compositions, over molds for insert molding, and tool adaptations including engineering changes.  

Contact Michiana Global Mold today to learn how our vast experience, knowledge, and technical capabilities will add value to your supply chain.  We partner with our customers from the beginning, providing quality, precision molds for a wide array of applications over various industries.  Michiana Global Mold is an ISO Registered injection mold construction supplier, providing quality class  steel molds since 1952.  

Custom Plastic Injection Mold Making

A custom plastic injection mold maker has expertise with designing a plastic injection mold to manufacture a unique plastic part.  Custom injection mold making is used in several industries, especially those requiring new parts with new model releases such as the Automotive Industry.

When new projects require complex parts that fit into existing assemblies, or critical components used in interior automotive parts, you need a precision custom plastic injection mold making company.  At Michiana Global Mold, no part is too complex.  We excel at designing and manufacturing precision, tight tolerance, custom designed molds for critical components.  Our specialty is providing quality precision tools for complex, custom parts.  

Michiana Global Mold employs highly skilled designers and engineers, utilizing the latest technology to design the perfect tool for your complex part requirements.   Using Unigraphics software, we can create 2D and 3D models of the optimum design, quickly identifying critical dimensional areas prior to cutting steel.

Our designers and journeyman mold makers have vast experience designing complex tooling, even molds that require cam action or customized ejection systems.   Your custom injection mold will be designed to run in your press, and within your unique environment.   We’ll take your water lines and mounting plate into consideration for optimum placement, avoiding any future discrepancies with a smooth-running mold.

Full Service Injection Mold Making Supplier

Michiana Global Mold is a full-service injection mold making company, with over 600 years of combined experience.   Our knowledge, expertise with mold making, and vast resources give us the opportunity to provide the best value to our customers.  

We have a partnership with Modular Mold Solutions, located in China, giving us the ability to source tools overseas while still providing the same quality that you expect from a superior domestic mold making supplier.   

Both of our locations, in China and here in the US, are registered to ISO9001, following a strict quality policy in all processes.   We practice continual improvement on a regular basis, passing savings onto our customers with improved efficiencies and consistent quality.  

 

Michiana Global Mold is a full-service injection mold making company, providing high performance plastic and rubber molds to a multitude of industries including automotive, consumer products and electronics since 1964.  Contact us today to learn about our  free design consultation  and multi-tool discount for high volume projects.  

Partner with an Experienced Injection Mold Maker

Injection mold making is a very critical, precision process that requires not only knowledge and resources, but also experience.  Experienced journeyman mold makers make all the difference in the world when it comes to creating a quality crafted injection mold versus a sloppy tool that barely makes the mark.   Having experience with building precision tools for a multitude of applications gives invaluable skill that cannot be learned anywhere else.  An experienced journeyman mold maker is a valuable component of the injection mold making process.

Experienced Journeyman Mold Makers at Michiana Global Mold

At Michiana Global Mold we employ a highly skilled design and engineering staff and master journeyman mold makers with in-depth knowledge and vast experience in designing and constructing precision, complex tooling.  We partner with you from the very beginning, coordinating on every aspect of your project with clear, transparent communication.  

Our experienced team draws on traditional methods, combined with our cutting-edge technology, to provide the best solution for your precision injection mold requirements.  Our large capacity facility in Indiana is equipped with conventional EDMs and wire EDMs, CAD/CAM engineering equipment, CNC milling centers, grinders, drills and saws.  

One of our knowledgeable staff can assist you in determining the best type of tool for your project, with the most cost-efficient method while not compromising precision quality.  Michiana Global Mold specializes in manufacturing tight tolerance, complex, precision tooling.  We have the experience and the resources to provide the perfect tool for your project, on time and within specification.  

Michiana Global Mold provides custom injection mold making for any required tooling operation.  We are experienced at manufacturing hot and cold runner molds, hot to cold molds, insert molds, shuttle molds and prototypes.  Our production molds are built with experienced craftsmanship, and only the best in quality components.  

Michiana Global Mold has been in business since 1964, serving the injection mold making industry for over 50 years!  We are an ISO9001:2015 Registered mold making facility with domestic and off-shore molding capacity.  We have the experience and the resources to provide quality molds for any molding application, and the resources to handle multi-tool packages within specification, and on time.  

Value Added ISO Registered Mold Makers

Sourcing with an ISO Registered injection mold maker gives added value and valuable benefits with assurances of providing a consistent high quality product.  Michiana Global Mold is an ISO Registered mold maker, providing top quality, high performance complex tools for the injection molding industry for over 50 years!  

We are experienced at designing injection molds for challenging parts that require tight geometric tolerances.  Michiana Global Mold combines years of experience with the latest in technological advancements to deliver complex injection molds to manufacture parts within your specifications as precise as +/-.001”!

Strict Quality Policy at MG Mold

At MG Mold, following a strict Quality Policy is something we’ve done since 1943.   Conforming to the globally recognized ISO standards only reinforces to our customers and partners that we hold the quality of our product, and your satisfaction in the highest regard.  We are experts at constructing complex injection molds for critical components, satisfying the Automotive industry for decades as a core supplier.  

Our Continual Improvement projects result in cost savings to you, as we improve our efficiency and cycle times, while still providing superior long lasting, high performance injection molds.  

Our Advanced Quality Planning Procedures (APQP) include a thorough evaluation of all design considerations, no matter the type of tool required.  From cavity inserts, prototypes, hot or cold runner tools, we conduct a thorough evaluation to develop the most appropriate design for and construction for your tool.

Our use of CAD/CAM sophisticated equipment provides automated efficiencies that we pass onto our customer.  You benefit from the years of experience and advanced computer systems utilized at Michiana Global Mold, in terms of a quality built tool producing the desired part within specification, delivered on time and most importantly manufactured properly the first time.  

We provide part sampling, and minor adjustments with our full-service mold construction, delivering a quality part on time due to a systematic approach and following our detailed checklist for designing diverse types of molds.  

Contact Michiana Global Mold today, a custom precision injection mold maker registered to ISO9001:2015.  We follow a detailed checklist for every tool design, assuring your total satisfaction with a high performing, top quality injection mold.  

How a Prototype Mold Can Benefit Your Project

When engineers are designing new models of mass produced parts, you want to know if your new design will function as it should in the assembled product.  One way to verify your new part design is with a Prototype mold.

A Prototype mold can be constructed for less money than a full size standard mold to verify the functionality of the desired part.  Prototype molds are typically constructed with a less expensive material such as aluminum, non-hardened steel or P20, and usually contain just one cavity rather than multiple cavities, as only one part is needed to verify dimensions and part function.

This is advantageous in many industries such as the Automotive industry, where new model year automobiles combine new parts with current parts on the same vehicle.  In some designs, not all parts are updated or replaced yet all parts in any particular assembly must function perfectly together. A Prototype tool will give you the flexibility to test out and alter if need be, a newly designed part that will function to your specifications.  

Advantages of Prototype Molds

Since Prototype tools are constructed with less expensive, and less sturdy steel, it can only be used to produce short lots for testing purposes.  The material would not hold up for any large or standard production runs.  

This can still be a very worthwhile investment, however, especially if you are uncertain as to how the dimensions on one part will fit with your application, or if you just want to test it out prior to building the production mold.  Since the Prototype tools is quite economical, it could be advantageous to start here if you have any questions about a new project.

Michiana Global Mold has the resources, the experience and the experts on staff to build your Prototype tool to your specifications, allowing you to test your products prior to investing in standard mold bases.

Michiana Global Mold has vast experience helping engineers and designers achieve their geometrical and dimensional goals with design assistance and Prototype Mold Construction.  Contact Michiana Global Mold today to see how we can assist you with your project development goals.  

Thermoplastic Molding

Injection Molding with Thermoplastic Resins
Thermoplastic molding refers to the process of injection molding thermoplastic resins.  Thermoplastics is a type of polymer that melts and becomes pliable when reaching a certain temperature, allowing it to be molded into various forms.  This type of polymer can also be ground up and reused after hardening, as opposed to thermoset polymers, which cannot be melted and used again.  The third type of polymer is elastomer, which can also be thermoplastic, in which case this type of material is referred to as thermoplastic elastomers.  Thermoplastic resins are the most common type of material used in the injection molding process.
The Molding Process
The equipment required for thermoplastic molding is the same: a press, a steel mold, and plastic resin.  The resin is poured into a hopper on top of the press, and is then drawn into the press where it is heated in a barrel and injected into a steel mold where cavities carved out by journeyman mold makers form the molten plastic into the shape desired.  The steel mold is usually equipped with water lines running through it to cool the parts before the mold opens and parts are ejected.  Each time the mold opens, molds parts, and ejects them is called a cycle.  The typical injection molding cycle is measured in seconds.  Decreasing the cycle time can lead to improvements in efficiency and the bottom line, as long as it does not jeopardize the functionality of the part.
The Mold
The mold is the steel frame that contains the carved out cavities to actually form the part.  Every injection molding job requires a steel mold to form the molten material into a usable functional part.  There are different types of molds for different applications, but the most common is a class A hardened steel mold, capable of producing hundreds of thousands or millions of parts without wearing out. 
For the typical thermoplastic molding process, a steel mold will run in a horizontal molding press, meaning the mold will open and close on a horizontal plane.  In this case, when the mold opens and ejects the parts, the runner is also ejected.  The runner is the residual molten plastic that hardened in the channel getting the plastic to the cavity in the mold.  This is true of a cold runner mold, which is the most common injection mold.  A hot runner mold, in contrast, injects plastic directly into the cavity from a nozzle, and therefore has no runner.  A hot runner mold can assist with automation, but it is more costly than the more common cold runner mold. 
Equipment Required for Automation
While the necessary equipment is the same, a molder can invest in auxiliary equipment to automate the process and run parts without an operator, and sometimes even in a ‘lights out’ environment.  A vacuum conveying system sucks the plastic resin while in pellet form from a drum or gaylord into the hopper on the press.  As long as enough resin material is in the drum the conveying system will automatically supply a steady stream of thermoplastic resin into the press.  There are ways to regulate the amount of pellets drawn into the hopper at a time.  Some molders even have ways to measure the moisture content of material, and dry it accordingly before it enters the press.  Some molders use a moisture analyzer when required. 
Sprue Pickers Assist with Automation
When a cold runner mold is used in a horizontal press, the runner will eject with the parts and either drop to a bin below, or be grabbed by a robotic arm called a sprue picker.  A sprue is another term for a runner.  Sprue pickers assist in the automation process because it separates the parts from the runners, allowing the parts to collect in a tub by themselves and not need to be sorted or separated from the runners. 
Process Monitoring Adds Consistency and Reliability
A Process Monitoring System should be utilized for automated molding as it will monitor, as the name implies, the process as it is happening.  If something began to run out of spec, such as temperature or pressure, an alarm would sound to alert a technician.  These monitoring systems also function as material resource planning software, allowing the user to input specific job information and schedule production. 
These are some of the ways a molder can automate the injection molding process. If precision parts manufacturing is required, automation could assist to provide to a consistent and reliable process. 

Contact Michiana Global Mold today to see how we can reduce costs on your plastic part requirements.  

Resin Injection Molding

Molding With Plastic Resin

Resin injection molding is the manufacturing process of molding raw plastic pellet into usable parts.   Thermoplastic resin is the most common type of plastic used in the polymer molding process.  The resin, or plastic pellets, is used by injection molders to make parts for a wide variety of industries. 

Custom injection molding is the process used by custom molders to make parts that are designed by others, typically engineers in the Automotive, Aerospace, Consumer Electronics, or Medical field.  Injection molding is also used for the Furniture, Construction, and Toy industries, although precision molding is required for the former mentioned industries requiring a high level of quality with tight tolerances.

Each resin has a melt temperature when it becomes pliable, which allows it to flow through an injection molding press, into a barrel and screw, where it is injected with pressure into a steel mold forming the desired parts.  After forming, the mold ejects the parts and closes again to prepare for another cycle. 

Characteristics of Thermoplastic Resins

Thermoplastic resins have a unique ability to be strong and durable, yet also lightweight which makes is a desirable material for several functional parts. They can be reinforced with glass filled polymers, or they can have a rubber like appearance, and several variations in between.  They can be made into virtually any color, size or shape.  This flexibility is the main reason that plastic resins are the material of choice for supplying various industries with necessary functional parts.  Some examples:

·         Polycarbonate

·         Polyethylene (low or high density)

·         Polyethylene Terephthalate (PET)

·         Polypropylene (Acetal)

·         Polyphenylene Ether (PPE)

The experienced molder has all procedures in place to provide full traceability throughout the resin injection molding process up to and including shipment of quality parts that meet or exceed customer specifications, along with proper documentation.  Contact Michiana Global Mold today to see how we can help you with your injection molding needs.

Finding a Chinese Injection Mold Provider Consideration List

Searching for a China injection mold provider can be incredibly difficult and time consuming. There are plenty of blogs and articles that cover different aspects of what you need to consider, but you"ll need a list. This ensures that you look at all of your potential China injection mold source options and the range of questions you need to ask.

Remember, the cost is not your only consideration. Things like shipping time, communication, and QA process play very important roles in determining if a particular China injection mold provider is cost effective.

Your Sourcing Options

You have three options for finding a provider in China:

• Direct Chinese source
• Broker who recommend and negotiates with a Chinese source on your behalf
• Domestic provider with a Chinese partner

Initially, this list appears to reflect the cost in ascending order. A direct source will often appear to be the most cost effective source and a domestic partner will appear to be the least cost effective.

However, when you take the following considerations into account, you will see the initial cost for the domestic provider has some distinct advantages, including easier negotiations, design time, and predictable delivery times.

Considerations and Questions

When you talk to each of your potential sourcing options, the following considerations and questions will help you determine if the source is likely to meet your needs.

Communication

This is one of the biggest potential issues, particularly during the design phase. You need to be able to talk to the people who are responsible for the designs. There are several potential communication issues to consider:

• Time zones can pose a problem if you work directly with someone in China
• Designs can be more difficult to finalize when you cannot speak directly to one of the professionals working on the design
• Shipping times may be off because of holidays, so you need to know the production schedule for the entire time your product is being processed

Planning

Planning is one of the most important aspects as it sets the tone for the entire project. Here are the things to consider for the planning phase:

• Materials
• Design time
• Production time frame

Quality Assurance and Shipping

Make sure that you discuss your QA needs and shipping expectations. If you are working on a tight deadline, you need to make sure that the product is high quality and can be turned around quickly.

The Right Choice for Chinese Injection Mold Makers - Domestic Versus Offshore

Finding the right China plastic injection molding provider is a difficult decision. With a number of different considerations to make, you want to get it right the first time. You will also need to be prepared to negotiate.

Research

Research is essential to avoid making the wrong decision, which can cost you not only money but a lot of time, and potentially customers. There are three sourcing options:

• Direct sourcing
• Broker sourcing
• Domestic sourcing

Each of these options has their own appeal. To help you determine which is right for you, consider the following three points:

• The material the China plastic injection molding uses
• The kind of quality sampling provided
• The lead and shipping times

Finding the Right Material

The material used for the China plastic injection molding is one of the most important aspects because it determines the durability of your final product. If you do not specify what materials you want used at the beginning, you may end up with a product that does not meet your expectations.

Materials Originating in China

Many Chinese mold makers have their own material providers. This means without specifying the type of material, you are almost guaranteed to have a final product made that uses steel produced in China.

The Chinese regulations and standards are typically lower than steels made in Europe and North America. As a result, your final product may wear down faster, be more fragile, and require more frequent replacements.

Materials Originating in Europe

This is easily the most cost effective material. European standards are comparable to the standards of North America, but the product has a much shorter distance to travel.

Testing

Mold testing often requires the use of a representative to conduct a review at the facility to check the functionality and quality of the product. If you have tune-ins built into the contract, you will have a better product by the time you send your representative to conduct the review.

Lead Times

The shipping lead times are important because the different sourcing options handle shipping differently. Having excessively long lead times could end up negating cost savings. The following are important to know before you sign anything:

• Time zone difference for communicating and shipping
• Chinese holidays
• The receipt of sample shots from T-0
• Import duties

You need to know how each of these are handled so that you can plan accordingly.

Choose the Right China Injection Mold Supplier

Finding the right China injection molding supplier can be a very time consuming endeavor. You have three different channels to consider:

• Find a direct Chinese mold maker
• Hire a broker
• Work with a domestic provider

Each option has its own advantages and disadvantages.

Direct Chinese Mold Maker

Initially, this will seem like the most cost effective method of getting a reliable China injection molding supplier. You won’t have to pay for a middleman, substantially reducing the initial cost.

However, it can end up being the most costly. The biggest issues are the language barrier and additional QA efforts. It will be much more difficult to negotiate if you do not have a native speaker who can work with the supplier. While they will surely have an English speaker, you will need someone who speaks their language as well. This can be very costly. You will also need to manage more of the QA to ensure the product meets your needs.

China Injection Molding Broker

The issues you could encounter with a direct provider can be largely avoided by using a broker. It will also look a bit more expensive up front. This is because they have established connections to help you find the right provider, as well as managing the monetary conversions.

Do keep in mind that they are only brokers. You will not be able to discuss specifics with them, only the people at the companies they recommend. This can also create lag time in getting your questions answered.

Domestic Providers

Domestic providers will appear to be the least cost effective China injection molding provider, but ultimately, they can save you a lot of time. Not only will you avoid having to research companies, they have the necessary experts to answer your questions. This substantially speeds up the design and development process, reducing the amount of time required to complete the project. They also manage the QA aspects, so that you can focus on other projects.

Initially, they are the most expensive option. However, cost is the only major drawback, and it usually ends up being far less costly than it appears at first. Because you save time and have the necessary experts to answer your questions, the final cost for domestic providers is a lot more competitive than you may initially believe.