Automotive Mold Makers Excel with CAD/CAM

Computer aided design and manufacturing (CAD/CAM) is a necessity to injection mold makers around the globe.  Injection molding today is complex with precision parts requiring tight dimensional tolerances.  Thermoplastic resins provide many benefits over other materials and are being used in many critical applications worldwide, including components for the Automotive, Aerospace and Medical industries.  Meeting these tight tolerances with complex injection molds requires the skilled use of CAD/CAM by an experienced injection mold design engineer.

CAD/CAM Delivers for Automotive Suppliers

Automotive OEMs demand the best from their suppliers, and expect perfection with zero defects, continual improvement plans and even cost reductions.  In order to satisfy the demanding requirements of the Automotive industry today, injection mold makers must operate in a lean and effective manner.  

Michiana Global Mold utilizes the latest in technological advancements with CAD/CAM design and mold making capabilities.  Our skilled design engineers have decades of experience constructing custom, precision molds used in critical applications by OEMSs worldwide.  

Our design engineers can quickly identify problematic dimensional areas, and address all concerns with the customer via easy file sharing.  Michiana Global Mold is experienced with UniGraphics, SolidWorks, Mold Flow Analysis, and various computer aided milling machine centers.  

Michiana Global Mold Offers Modern Injection Mold Making

View Michiana Global Mold’s Equipment List and see why we are you one stop full service injection mold making and service facility.  We currently have a full line up of EDM and Milling centers with Charmilles, Hurco and Hansvedt to name only a few of the best names in mold making machinery.   We have top of the line wire EDM, grinding, turning and drilling equipment, driven by technologically advanced CAD/CAM software and equipment.

Combining advanced equipment with the skill and experience of our design engineers and journeyman mold makers, we are able to offer to you high quality precision tooling, on time and within your budget.

Michiana Global Mold is an ISO Registered mold making facility serving OEMs worldwide with high performing, precision injection molds for complex components.  Contact us today for a FREE cost estimate of your next injection mold project requirements.  

Advantages of Prototype Injection Molds

Constructing a prototype injection mold has many advantages to a successful launch of an injection molding program.  Prototype tools give a molder a chance to try out a new design, prior to investing in a large multi-cavity full size injection mold.  Some prototype tools are even constructed with just a prototype cavity, allowing for additional cavities to be developed later after perfection of the prototype.  

Prototype tools are advantageous when using a new thermoplastic resin that the molder may not be familiar with.  A prototype gives the advantage of learning how a new material will melt, flow and fill critical dimensional areas.

A prototype also gives a molder a chance to try out a new design for a part that may have to fit into another larger assembly.  Constructing a prototype tool will give the molder a chance to produce a prototype part to test out functionality, either in larger assemblies or even on an automated assembly line.  

Constructing a prototype tool is a very inexpensive way to test out new parts without an initial major outlay of cash.   Prototype tools are typically constructed with less expensive material than a production tools, therefore are not made to stand up to high volume production but rather a few short production lots for sample testing.  

While production tools must be constructed with hardened steel, a prototype can be made of P20 or non-hardened steel, or even aluminum, as this is adequate to produce sample parts for testing purposes.  Prototypes are used in many industries where an initial small investment into a mold for testing purposes is well worth it prior to constructing a high-volume production mold.  

Michiana Global Mold has vast experience assisting engineers and designers to achieve their dimensional goals with design assistance and Prototype Mold Construction.  Contact us today for a FREE design consultation and to see how we can assist you with your project development goals.  

Injection Mold Design for Engineering Resins

Thermoplastic engineering resins are the most common type of plastic resins used in the injection molding process.  With many different types of plastic resins each with their own unique properties, it takes great care and consideration to properly design and construct a mold for use with thermoplastic resins.   These highly useful polymer resins have varying properties of elasticity, resistance to temperature, corrosives, shrinkage and right down to the exterior finish such as a matte or a glossy finish.  

Shrink rate is a very important property of thermoplastic engineering resins used in injection molding, as the cavities must be carved out to accommodate to this shrink rate.  If shrink rate is not accounted for properly, a part may shrink too much after cooling and deviate from customer requirements. Knowing the cooling and shrink rate of the polymer resin used for any molding process is of the utmost important to the journeymen mold makers constructing the tool.  

Cooling rate is also important for the part to become completely solidified prior to ejection.  Cooling rate must be configured into the injection molding cycle time, to ensure proper cooling and ejection without damaging the part.  

Each polymer resin will have a MSD sheet, Material Safety Data sheet along with material specifications clearly defined in each numbered lot of all thermoplastic resins.  If working with a new material, a mold designer may prefer to use Mold Flow Analysis, for a computer simulated demonstration of how the plastic material will melt, flow and fill.   Predicting the flow of thermoplastic resins prior to cutting steel is vital for accurate geometrical tolerances in the final product.  

Even with a material spec sheet which is necessary, nothing helps a skilled mold designer more than experience.  Skilled mold design engineers are very familiar with the various properties of engineering resins allowing for precise mold construction with even the most specialty of molding resins.  

Michiana Global Mold is an experienced mold design and construction company, with vast experience with various thermoplastic resins used in injection molding.  We employ highly skilled journeymen mold makers and expert design engineers to satisfy even the most demanding of customer requirements.  We tackle the complex mold designs that other companies shy away from.  For complex, precision molds that must meet tight tolerances, contact Michiana Global Mold today for superior mold design and mold making services.

Contact Michiana Global Mold today to speak with one of our skilled mold designers and learn how we can assist you with your next injection mold making project.  We are an ISO9001:2015 Registered mold making company with vast experience constructing custom, precision injection molds using various thermoplastic engineering resins.  

Plastic Injection Part Design with Ribs and Bosses

Ribs are often used to add strength and stiffness to plastic parts in critical areas or geometric designs where thin walls exist.  This makes the part stronger with added support but can also cause sink marks on the exterior side of the part, where the rib comes together to meet the main wall in the part design.  When using ribs to add support, remember the general rule that the rib should not be more than 60% of the wall thickness.  Adding ribs to an injection mold design will increase costs, and may require EDM processes.  

Working with an experienced injection mold manufacturer will give you the best value for your investment.  Skilled journeyman mold makers and experienced injection mold design engineers will have the best knowledge of where to place ribs for added support and how this will affect the tool design, and the cost.

Mold making companies today can provide you with a two-dimensional computer aided design to show you exactly how your injection mold will produce the required plastic part, and alert you to any problematic areas ahead of time.  

Bosses are a very common feature in many plastic parts, and comes from the word emboss, which means a raised stamp or design, standing out on the surface.   Bosses that are designed with too thick dimensions can cause sink marks similar to the use of ribs.  Utilizing the proper ratio of ribs to bosses a molder can reduce or eliminate unsightly sink marks caused by either feature.  

Ribs used to connect boss areas to a side wall can add strength while avoiding sink marks.  Sharp corners are another area where excessive stress can concentrate and adding small radii feature in this area can strengthen the corner and reduce excessive stress.

Michiana Global Mold is a full-service mold design and construction company, with vast experience in all types of molds.  We offer an ISO registered Quality System, state-of-the-art domestic mold building facility with off-shore partner, and decades of experience with precision, complex tooling.  Contact us today for a FREE design consultation and to speak with one of our highly skilled design engineers.

Molded Part Surface Finish and Ejection Methods

Injection mold designers must always take into consideration the surface finish required of the finished molded part.  The ejection system in the mold that removes the solidified parts out of the mold cavity or cavities has great impact on the part’s surface finish.  The most common ejection system uses ejector pins which can leave marks on the part, often referred to as witness lines.  

An experienced mold designer will position ejector pins in order to place witness lines in an area acceptable to the part print.  The ejection system and ejector pins are housed in the B side of the mold, extending into the cavity during ejection then retracting back into the mold.   Restrictions on ejection must be apparent prior to mold design, if ejector pins cannot be used without damaging the part, lifters can be utilized for proper ejection.  

The injection mold design must correspond to the ejection pattern and stroke of the press.  Michiana Global Mold is an experienced injection mold maker with in-depth knowledge of designing various ejection systems to meet customer specifications.  We use CAD/CAM Unigraphics software to design and develop a layout for the ejection system prior to cutting steel.   

In some cases, ejection systems must be designed around robotic arms that reach into grab the parts upon ejection.  These robotic systems are called ‘sprue pickers’, as sprue is another term for the runner that is also ejected with the part.  Some ejection systems automatically separate parts and runners, so that they do not need to be separated later.  

Whatever your part design, surface finish, or ejection system is required, Michiana Global Mold will design and construct a superior mold with flawless ejection for the specified part surface finish.  We are an ISO registered mold making company with an offshore mold making partner in China.  Contact us today for a FREE design consultation and to speak with a skilled mold engineer.

Domestic Mold Maker with Offshore Mold Capabilities

Buyers of injection molded components are continuously faced with pricing challenges, they must provide to their customers the absolute lowest cost for injection molded components, and that begins with the cost of the tool.  Investment into the plastic injection mold is often the largest up-front costs injection molders face, and this price can make or break a contract with an OEM seeking the lowest cost world-wide.  

Today’s global economy is far different than two and especially three decades ago, prior to NAFTA and the mass sourcing of manufactured parts to overseas companies.  The cost difference is not as steep as it used to be with offshore companies rising to the occasion, improving their supply chains and quality systems and their overhead along with it.  There are still some attractive cost strategies to be used, however, if you have the right connection and know how to go about sourcing with offshore companies.  

Where to Begin Sourcing an Off-Shore Injection Mold Maker

It can be overwhelming trying to figure out how to get started working with an offshore company, specifically a mold making company in China.  Without proper planning and implementation, the endeavor can end up costing you more than it should.  

You are sourcing overseas to save money that you can pass on to your customers, you surely don’t want to invest more into it that you will get in return.  In many cases, having an overseas source for molds determines whether you get the contract or not.  It is not an option of whether you have a mold maker in China, it is a necessity and the only question is how to go about it.  

Domestic Sourcing Provides Return on Investment

Rather than try to contact a Chinese company directly, or use a broker to help you, working with a domestic mold maker with partnering companies in China gives you quick return on your investment.  With a domestic provider, you do not have to worry about the language barrier, currency conversions, lead times and most importantly – the quality of the tools you are sourcing.  

Michiana Global Mold is a domestic mold making company with a partnership in China, providing full-service overseas injection molds, headache and hassle-free to you.  We take care of everything from the language barrier, quality concerns and lead times, giving you one point of contact in our US location to fully coordinate all aspects of your tool build.  

Both of our mold making facilities in the US and in China are registered to ISO 9001, following a strict quality policy to provide tools to your specification.  We use only North American or German steel, and provide sample parts and all final inspections from our US location.  

We have vast experience with all types of tools including prototypes, insert cavities, three-plate tools, hot-runner tools and shuttle molds.   Download our FREE Guide to Sourcing Your Tools in China, and let Michiana Global Mold provide you with domestic support and offshore pricing.  

Michiana Global Mold is a leader in plastic injection mold making, serving the Automotive and various industries since 1964.  We offer high-quality, precision tooling from our domestic or overseas location, on time and to your specifications.  Contact us today to learn more about our offshore mold making capabilities.  

Injection Mold Makers for Precision Parts Manufacturing

Injection molding companies that manufacture precision parts are often in need of a precision injection mold making company to add to their preferred vendor list.  Many quality and purchasing engineers in various industries are searching for a custom mold making company with high precision capabilities to manufacture critical components.

Some industries that require vendors with precision capabilities to produce to high performing parts and components are:

• Automotive
• Aerospace
• Military / Ordnance
• Medical / Pharmaceutical
• Consumer Electronics

Suppliers to OEMs in these industries must meet stringent requirements, as all suppliers play a vital role in the quality of the end product.   An injection molder must be working with a quality tool that is designed and manufactured to produce a perfect part to the customer specification.  When working with a quality tool, and the specified material, an experienced molder will produce precision parts to specification.   

In addition to the molding parameters such as the size of press, and the material used, the mold design has vital impact on the quality of the parts produced in the manufacturing process.  

Mold Design for Precision Parts Manufacturing

Producing precision parts consistently to customer specifications requires a flawless mold.  The mold design will be based on the part design, usually provided by the customer.  In some cases, an experienced mold designer can assist with reverse engineering for new product design.  

Experienced mold design engineers will use computer aided design (CAD) software to assist with an injection mold design, providing detailed prints that can be shared with the injection molder for collaboration on critical areas.  When necessary, mold flow analysis can show the mold maker, and the injection molder a detailed computer simulation of how the material will melt, flow and fill.

Precision parts molders need a precision mold maker in their vendor list, a mold maker like Michiana Global Mold that offer value added services with custom injection molds within specification, and delivered on time.  For full service mold making and tooling services from an experienced, professional and high performing mold making company, contact Michiana Global Mold.  

Michiana Global Mold is a leading mold making company supplying injection molds to OEMs worldwide for critical precision parts manufacturing.  Contact us today for a FREE design consultation and to learn about our multi-tool discount program.  

Mold Design and Automated Injection Molding

When an injection mold designer begins a development of the mold design, they must be aware of the environment in which the mold will run.  This includes the size and type of press the mold will run in, the material used for molding, and any auxiliary equipment used for automation as the location of tie bars and cooling lines must not interfere with setting and running the mold.

Vacuum Conveying System

A vacuum conveying system is an automated way to get the material into the press, with the right suction and force.  Vacuum conveying systems suck the material while still in pellet from the gaylord or drum into the hopper of the press, providing a steady flow of material for continuous production.   Vacuum conveying systems pull in a steady flow of material, and control the amount of material in flow to the press, and are also helpful with controlling the moisture content in the material.  

Sprue Pickers Aid Automation

Sprue pickers are robotic arms that reach into the press and grab the runner when the mold ejects, instantly separating from it the parts which can then fall into a bucket or onto a conveyor belt.  Some robotic sprue pickers reach in and pick up the runner then drop it either into a separate bin, or directly into a grinder where it can be ground up and reused as regrind material.  

Process Monitoring

Injection molders use process monitoring systems to constantly monitor the press settings such as temperature and pressure, alerting an operator if the job begins to run out of specification.  Some monitoring systems also provide material resource planning functions, tracking job due dates and material inventory for scheduling of jobs.  

All of the additional auxiliary equipment must function properly and work in conjunction with the mold when it opens and closes and operates on the tie bar.

Michiana Global Mold has vast experience designing and manufacturing molds adhering to customer specifications and each unique environment.  Contact us today for a FREE design consultation and to learn how we can assist.  

Mold Design Considerations for Thermoplastic Resins

The most common type of polymer used in injection molding is thermoplastic resins.  There are many different types of resins with various properties to meet part specifications for functionality.  When designing injection molds, the engineer must take into consideration all properties of the resin specified for the produce including adhesion, elasticity, resistance to high temperatures, shrink rate, resistance to corrosives, and desired finish whether matte or polished.

The cooling and shrink rate are of the utmost importance, as some parts with a high shrink rate will need the cavity designed accordingly so the finished product will cool and shrink within specifications.  Cooling rate is also important for ejection, as the resin must completely solidify prior to mold ejection.

When an injection molded part has a critical functionality, mold flow analysis may be helpful in determining resin flow into tight geometric areas.  Mold flow analysis clearly shows with computer aided simulation how the resin will flow as determined from its properties.  Predicting how thermoplastic resin will flow in the mold and cavities prior to cutting steel can be a valuable tool in avoiding costly mistakes.  Conducting the proper advanced quality planning with mold flow analysis can greatly improve lead times.  

Most journeyman mold makers will already possess the knowledge of hos particular resins flow just from experience.  A skilled design engineer with experience in manufacturing molds will have the knowledge to design the tool to produce a part to print specifications, with the chosen resin properties playing a huge role in tool design.

At Michiana Global Mold, we have been providing high quality precision molds for over 60 years, possessing more than 500 years of combined experience.  Our staff of highly skilled design engineers and journeymen mold makers are the best in the business with vast experience in various thermoplastic resins.

Contact Michiana Global Mold today to speak with one of our skilled and experienced mold designers to learn how we can assist you with your injection mold requirement.  We are an ISO9001:2015 Registered mold making company with vast experience constructing custom, precision injection molds for various industries.

Expert Brass Forging Die Manufacturer

Copper and brass forgings provide high density parts with very accurate dimensions, achieving a high level of consistency.  Brass forgings are used in several commercial and industrial applications such as automotive, aerospace, marine, transportation, plumbing, lawn and garden, heating and cooling and even the medical industry.  Brass forgings are also used to provide durable strength in architectural applications.  

Due to the precision required of brass forgings used in critical applications, you need a brass forging die maker with expertise in tool making skills.  Michiana Global Mold is a full-service tool and machine shop with vast expertise in manufacturing various molds and tooling, made with top quality components and precision accuracy.  

We have a large capacity modern tool making facility located in the heart of the Midwest in Mishawaka, IN, where we have been supplying quality molds and tooling for over 50 years!  We specialize in complex, precision tooling and brass forging dies, manufactured to your specification within +/- .001”, and on time.  

Michiana Global tackles the complex designs and intricate tooling that others shy away from.  With confidence and experience, we can manufacture your brass forging dies within your tight tolerances, and deliver high volume projects on time.  We manufacture forging dies with a heat treated and polished finish, for single or mass produced production requirements.

With a full-service tool shop, we also do engineering changes if necessary, saving you time and money.  We utilize a full line of CNC machines manufacturing brass forging dies with cost effective, efficient solutions, giving you the best value.   

Our expert design an engineering team can provide a free design consultation or provide reverse engineering services with our experience and CAD/CAM software and equipment.   We adhere all processes to our strict quality policy as an ISO registered mold and machine shop.  

Established since 1964, Michiana Global Mold has over 50 years of experience providing custom, precision injection molds, tooling and forging dies.  Contact us today for a free design consultation and to see how we can save you money on your procurement of brass forging dies.  

Hot-to-Cold Injection Mold Making Experts

Most injection molders and injection mold makers are well familiar with the standard mold base, consisting of two halves, referred to as the A and B side of an injection mold.  The standard mold base will have two sides, and gates where the plastic will flow into the mold, through a ‘channel’ to get to the cavity or multiple cavities where the parts will mold.   This standard mold base is also called a cold runner mold.  

When the polymer resin hardens in the cavity to form the part, it hardens in the channel as well, which is also called the runner or the sprue.  In most cases, the runner is scrap, and will either be ground up and kept in raw material inventory as regrind to possibly be used in future jobs that will allow it, or it will simply be thrown away.  

Some injection molders grind up runners and keep the regrind material, but it can pile up and become an eyesore as most injection molding jobs require the use of 100% virgin material.  Even if it can be reused, it’s value is greatly diminished if it is stored in inventory.  Some molders feel it’s not worth the space on the floor to keep regrind material.  

If this runner is large, it can be a huge expense built into the part production, as the cost of the material is one of the biggest, if not the biggest expense of producing the part.   In some cases, especially for extremely small parts, the runner is larger than the part being produced.  In cases such as this it may be advisable to construct a hot runner mold.

A hot runner mold has a nozzle at each cavity supplying plastic directly into the cavity, rather than flowing through a ‘channel’, creating a runner.  This is a big saver if you can avoid creating a large runner for a high-volume production job.  

Hot to Cold Injection Mold

A hot runner mold may be worth the investment in cases of excess waste with high volume, although it is typically quite a bit more expensive than a cold runner mold.  Another option is called a hot-to-cold mold which is a hybrid of the two.  

Rather than have a nozzle at each cavity, there is a nozzle supplying a shortened runner system, supplying material to more than one cavity, thus greatly reducing your material cost.  A benefit of a hot-to-cold mold as opposed to a hot runner mold is the cost, it is generally less expensive as there are not as many nozzles and inner workings.  

A hot-to-cold mold is often the most economical option, providing significant cost savings with a reduced runner size, while not imposing the added cost burden of a full hot runner mold.  

Michiana Global Mold is experienced at constructing cold runner, hot runner, and hot-to-cold runner molds.  We have been in business for over 50 years, providing high performance tools with complex, precision designs.  Contact us today for a FREE design consultation and to learn more about how Michiana Global Mold can reduce your purchased injection mold costs.  

When Do You Need a Hot Runner Mold?

Avoid Costly Runners

A hot runner mold is desirable in situations where you would have a large runner that would go to waste, thus raising the cost with excess material.  While the cost of a hot runner tool may be more than a standard cold runner mold, an economic analysis may reveal that the cost savings could pay for itself in a reasonable amount of time.  This would be especially true if the material is a costly specialty raw resin.  

Improve Geometrical Tolerances

In a hot runner mold, the material is injected directly into the cavity through a nozzle, rather than flow through the runner system.  This is done with more pressure than a cold runner tool, and can improve filling and packing into critical dimensional areas.   The pressure utilized in a hot runner tool can improve consistency in the molding process, thus improving the quality of the parts.

Improve Cycle Time

Due to the increased pressure, a hot runner tool may bring an improvement in cycle times.  All plastic processors know the value of an improved cycle time as increased efficiency equates to increased profits.   When applied to a multi-cavity tool on a high-volume project, the savings in cycle time alone could be quite significant, not to mention improving lead times with production parts.   The volume of production required from the tool is a big consideration when weighing the benefits of a hot runner tool versus a cold runner tool.

Flexible Gate Location

A hot runner tool allows for flexibility with the gate location, which can be placed in the most desirable area for consistent filling and packing.  In parts with high visibility, gate location is important to the aesthetics as well as function of the molded product.

There are two different types of gating mechanisms for hot runner tools, a thermal gate or hot-tip gating system, or a valve gate.  With a thermal gate the nozzle hardens at the tip, allowing the parts to disconnect from the nozzle prior to ejecting.

In a valve gating system, a valve slides over the nozzle tip prior to ejecting, assisting with ejection if the material does not solidify completely in the tip.  

Michiana Global Mold has knowledge and experience designing and manufacturing precision hot runner tools for customers demanding a high level of quality.  Contact Michiana Global Mold today for a free cost analysis of your next mold building project.  

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.