Maintain Molding Specs with Preventive Mold Maintenance

The cost of an injection mold is usually the largest part of an investment into a plastic molding process with the exception of the molding press itself.   Capital equipment requires maintenance, with a preventive maintenance plan typically in place for all equipment to keep machinery and equipment running at optimum performance levels and to avoid costly repairs.  

The injection mold itself is no different, operating at optimum performance when a regular preventive mold maintenance routine is performed.

Each injection mold is unique to a particular program, and may be either a cold or hot runner tool, with single or multi cavities.  Some injection molds run only a few times a year to produce a production run then store for a while before it is needed again, and some molds supporting high-volume requirements run continuously in the press.  

Performing preventive maintenance on these high-volume molds is critical to consistent part production within customer specification.  The material the used in the molding process has great impact on the steel mold.  A glass filled nylon, for example, will put a lot of wear and tear on the steel vs. a simple polypropylene material.

Take the time to determine at which cycle intervals your mold requires cleaning, and you will continue to produce high quality parts without mold breakdown.  Some preventive mold maintenance can actually be performed right there at the press, while other PM intervals require a full break-down and thorough mold cleaning.

Preventive maintenance is vital for mold performance, and to meet production requirements.  Take the time to determine the optimum mold maintenance regimen for your injection molds, and provide consistently molded parts within customer specifications.  

Michiana Global Mold is a a valuable supplier to the automotive industry, providing complex, precision molds with our ISO9001 Quality Management System.  Contact us today to learn about our rebate program and to how we can save you money on your injection mold requirements.  

How to Source Injection Molds Overseas to Save Money

Figuring out how to source quality injection molds overseas with an injection mold maker in China can be a daunting task.  This endeavor can end up costing you more than it would be saving if not implemented correctly.  How do you know the quality of steel and craftsmanship that this foreign company will put into making your molds?

When providing a competitive foreign quote depends upon landing that big contract or losing it, don’t leave this huge business endeavor to chance.  Work with a domestic mold making company who can provide overseas sourcing, and overseas pricing, with the same domestic quality and service your project demands.

Offshore Mold Sourcing from Domestic Provider

Michiana Global Mold is a mold making company located in the Midwest, USA, with a business partner in China to provide the same quality in complex injection molds as our domestic locations.  Both facilities are ISO registered, following a strict quality policy in mold design and construction.  With our offshore mold making partnership, we take care of all overseas communication and quality inspections for a hassle-free transition for you.  With one domestic customer service contact, you will have tool status updates and assurances of quality with on-time delivery.  

Our Chinese mold making partner, Modular Molds, uses only North American and German Steel to construct molds built to customer KPC’s.  We supply Initial Sample Inspection Reports (ISIR), with final inspection conducted at our domestic location for complete assurances to full print specification.  

Michiana Global Mold has more than 50 years of experience designing and constructing complex, precision tools.  We tackle the challenging molds that other mold builders shy away from.   WE are a full-service mold making facility providing prototypes, insert cavities, cold-runner and hot-runner tools,  three-plate tools and shuttle molds.   Download our FREE Guide to Sourcing Your Tools in China, and let Michiana Global Mold assist with your offshore mold sourcing project.

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.  

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.

Plastic Part Design to Avoid Sink and Warp

Plastic injection mold designers must consider the resin chosen for the part manufacturing when designing the mold as this plays a very important role in meeting part specifications.  One characteristic of the plastic material that requires careful consideration is the cooling rate compared to the geometry of the part.

What is Sink

This plays an important role in the likelihood of parts developing sinks or warps, and can have significant consequences on successfully molding parts with consistent results.  The cooling rate is extremely important because as the part begins to cool it will always begin at the mold surface and move inward, toward the center.  If the geometry of the part is such that the part is too thick, the center area of the part will not solidify quickly enough.  This center stays molten long enough for it to cause stress on the area already solidified, pulling downward towards the center and leaving a sink mark on the outer surface.  

Avoid Sink in Plastic Parts with This Rule of Thumb

Ribs are used to add strength to plastic parts in thin wall or critical areas, but can also cause sink marks on the exterior side of the part.  When designing plastic parts to avoid sink marks, remember the basic rule to keep the thickness of the rib somewhere around 60% the thickness of the wall.  Following this rule of thumb should help to avoid sink marks during the cooling process.  

What is Warp

If a plastic part design includes areas of uneven wall thickness, stress can develop during the cooling and solidifying stage.  If this stress is excessive, warps will occur where thinner sections solidify faster than thicker sections.  

Avoid Warp in Plastic Part Design

When undue stresses due to transitions in wall thickness occur, plastic part designers can combat this by using a ramp.  Designers also use gussets in corners of some geometric areas to help prevent warping.  

Michiana Global Mold is an injection mold design and construction company with extensive experience in designing precision tools for complex injection molded parts.  Our skilled designers have vast knowledge of injection molding with various resins, and designing a mold to avoid common pitfalls in manufacturing.  Contact us today for a FREE design consultation and to speak with one of our knowledgeable 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.

Full Service Injection Mold Making Tool and Die Shop

For full service tooling and mold making solutions, Michiana Global Mold offers a wide range of mold making and tooling capabilities.   Our niche, and one area of expertise is constructing precision, custom injection molds for complex part production using quality North American or German Steel with modern equipment and technology.  We meet the tight tolerances and fast deadlines of the Automotive industry, and are a valuable part of many other industrial supply chains.  

Our services include much more than building new injection molds, however, and as a full-service Tool and Die Shop we can offer a wide range of comprehensive tooling services.

CNC / EDM and Wire EDM Machining

With the latest in modern equipment, Michiana Global Mold uses four Charmilles CNC EDM Machines, a Charmilles EDM HD20, a full line of Hansvedt EDM centers, and a 3R and Erowa Tooling Package.  Our journeyman mold makers are experienced in the latest CNC EDM and Wire EDM Machinery and Equipment offering efficient tooling services.  

Grinding

MG Mold has over a dozen Harig grinders alone, in 6 x 12 or 6 x 18 with Grind All attachments, 1 Reid, 2 Boyer, and 2 Proth and 1 Chevalier Hydraulic Surface Grinders.   We can grind any surface area of any product meeting the most demanding of tolerances.  

Milling

With more than 30 different Milling centers, we have the capacity to provide full service for even multi-tool programs with quick lead times.  Our full line of milling centers include 1 Hwacheon 20,000 RPM High Speed Mill, 2 Fanuc Robodrill 20,000 RPM, over a dozen Hurco CNC Machining and Milling centers, 11 Bridgeport Milling Machines and various other milling machines fill our large capacity production area.

Sampling and Inspection

Michiana Global Mold will sample your tool in the selected material, providing first shots to your specification prior to tool delivery.   We provide the highest of quality and inspection services

Engineering Changes and Tool Adaptations

For all tooling processes, including Engineering changes and tool adaptations call on your one stop, full service tool and mold shop, Michiana Global Mold.

Michiana Global Mold has been supplying high-performance tight tolerance precision injection molds since 1952!  Contact us today for a  FREE no-obligation design consultation for your next mold making or tooling project.  

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.  

CAD/CAM Delivers for Automotive Suppliers

Supplying the Automotive industry with plastic injection molds poses challenges unique to that industry, with complex designs, quick lead times and tight budgets.   Not to mention the tight tolerances required of molds designed for critical components used in assemblies for items such as air bags, brakes, throttle bodies and solenoids, and various electro-mechanical switches.  

Save Valuable Time with the Right CAD/CAM Software

With the right CAD/CAM software, an injection mold designer can save valuable long hours entering critical dimensions for automotive components.  The capabilities of computer aided designs can increase capacity so much that a mold designer can take on new business, and drastically improve lead times with current customers.  Most OEMs demand CAD/CAM capability of their injection mold suppliers, as the automotive industry is focused on increasing profit margins with quick turnaround, from any supplier.  

You have to have a fast response time as a valuable participant in the automotive supply chain.  The right CAD/CAM software can increase your value-added services with this important partnership.  

Increase Profit Margin with CAD/CAM in Mold Making

With faster response times and increased capacity comes an increase in profit margin.  Having skilled design engineers knowledgeable with your CAD design software is vital for increased productivity.  

Ease of Modifications and File Sharing

Most leading CAD/CAM software programs allow for ease in file sharing, enhancing advanced quality planning as designers, engineers and OEMs can view and adjust for critical areas.  Problematic dimensions are identified quickly and shared all design participants for quick and viable solutions.  

When incorporated with skilled and experienced designers, modifying and sharing CAD files is a valuable benefit.  Michiana Global Mold utilizes the latest in technologically advanced CAD/CAM software with skilled and experienced mold designers.  Our designers are experienced with SolidWorks, UniGraphics, Mold Flow Analysis, and all computer aided milling centers.  

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

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.  

Industry Leading Innovative Mold Makers

It takes an in-depth knowledge of the mold making industry, along with experience and resources to provide top quality high performing injection molds that meet demanding customer expectations.  Michiana Global Mold excels at manufacturing complex, precision tooling required of demanding industries such as the Automotive industry.  We have the knowledge, the experience and the expertise in constructing high quality injection molds meeting tight tolerances within +/- .001”.

Michiana Global Mold is one of the leading injection mold makers in the industry, employing a highly skilled staff of journeyman mold makers and top mold designers with vast experience constructing high performing complex tooling.  We excel at the precision components that other mold makers might shy away from, leading the industry with high-tech mold making equipment combined with vast experience and knowledge.  Recently featured on the “World’s Greatest” television show for our innovative mold making services, we are a valued supplier to the Automotive industry, meeting and exceeding our customer requirements.  

With locations in the Midwest, USA, and an offshore molding facility in China, we can offer high quality tooling at the best available cost to you.  Both of our locations are registered to ISO9001, adhering to our strict quality policy while performing continual improvement activities.  Total customer satisfaction is our number one goal.  

When you are searching for a new supplier for your injection molded needs, let Michiana Global Mold show you how we can assist with your procured mold making costs.  We more than 50 years of experience satisfying the stringent requirements of demanding industries with even the most challenging of injection mold designs.  

We are experienced with specialized CAM action, complicated ejector system and lifters, and will accommodate tooling to your molding environment and custom mounting systems for your presses.   Established in 1964, we have the expertise, the knowledge and resources to provide the best value with high quality and high performance tooling, at the lowest available cost to you.  

Contact Michiana Global Mold today to speak with one of our expert design engineers about a FREE design consultation, discounts and rebates on multi-tool projects.  We are one of the leading injection mold makers in the industry, providing complex precision tooling within your specifications, and on time.    

Injection Mold Making Technology

Injection molding is the mass producing of plastic parts with a steel mold, an injection mold, designed with cavities to mold the desired part.  Injection molding uses thermoplastic resins, also called polymers, typically in a raw pellet form, that melt and flow into the cavities in the mold, forming the part, then it is ejected once it hardens.  The time that it takes for the mold to close, plastic to flow into the mold, the polymer to set and eject upon mold opening is called the cycle time.  Injection molders are always looking for ways to increase the cycle time, as time is money and when you can mold a part faster, you can mold more per hour, per day and per week.  

A skilled injections mold maker will have the knowledge to design the mold with the most appropriate attributes to reap the best cycle time while still delivering the desired part to the customer specification.  Michiana Global Mold is accustomed to constructing complex, precision injection molds within +/- .001”, which is about the thickness of a human hair.  

Injection Mold Making Equipment

Injection mold makers are well familiar with the precision equipment used to carve out steel cavities, forming a perfect plastic part.   Computer aided design, and computer aided manufacturing (CAD/CAM) equipment is a key tool for designing a perfect tool.  The designers at Michiana Global Mold use Unigraphics CAD/CAM software to design the mold fit for producing a desired part.  This alerts the mold maker and the injection molder to any critical areas such as thin walls or a critical dimensional tolerance that must be met, prior to cutting steel.  

Milling machines, conventional EDM and wire EDM machines are a necessary tool, along with high speed CNC machines, drill presses and grinders.   Michiana Global mold, located in Mishawaka, Indiana with an offshore mold making facility in China, utilizes all of these mold making equipment tools, and more.  We have over 50 years of experience constructing complex tooling for demanding industries such as the Automotive industry where 0 ppm (parts per million) defects is the norm.  The key to a quality plastic injection molded part, is a quality injection mold.  

No one understands this better than Michiana Global Mold, your one stop shop for mold making and tooling services.  We do everything from constructing insert cavities and prototypes to full service high volume precision production tools.

Michiana Global Mold is Registered to ISO9001:2015, delivering custom injection molds to a wide array of industries demanding high volume long lasting performance with the best available pricing.  We offer rebates on multi-tool programs and discounts with offshore molding options.

Contact us today for a FREE design consultation, and to see how Michiana Global will provide value added services in your supply chain.

How is a Shuttle Mold Used?

A Shuttle mold is a mold system with one A side, and multiple B sides.  This is used in a vertical clamping press, as opposed to a horizontal clamping press.  A vertical clamping press is used for over molding, also referred to as insert molding.

Insert molding occurs when plastic is molded around an object such as a metal or even another plastic insert.  A shuttle mold system is used on a rotary table press so that there are two, three or sometimes four bottom sides, rotating around on the table allowing an operator or a robot to place the insert into the cavity in the mold.  When the bottom side spins around, the top half of the mold will come down vertically clamping onto the B side to mold plastic around the insert.  

This system can be labor intensive requiring an operator to load inserts, and unload molded product, unless the job is set up with automatic robots for this purpose.  This is different than most horizontal molding processes in which the there is one A and B side of the mold, sliding on a horizontal plane, coming together for the injection molding process, then the parts are automatically ejected with an ejector system falling into a desired location, usually a bin or box underneath the mold.  

Most horizontal injection molding jobs are fully automatic once the mold is set in the press, some can even run in a lights-out situation if automated auxiliary equipment is established.  A vertical molding press with a shuttle mold system typically employs an operator, although they can also be automated.  

Some examples of insert molding would be electrical wire harnesses that are partially encased in plastic, or even knives or silverware that have plastic molded around a metal object.   Shuttle molds are used in plastic injection molding for various industries including Electronics, Consumer Goods, Automotive, Aerospace and Military / Defense industries.  

Michiana Global Mold has experience constructing precision shuttle molds, and virtually any other type of plastic injection mold base used in various industries.  We are a valuable supplier to the Automotive industry with complex tools meeting tight geometrical dimensional specifications.  Contact Michiana Global Mold today, and ISO9001:2015 Registered mold maker.  

Mold Maker for Consumer Products

Consumer products is a very broad industry, encompassing everything from appliances, electronic components, household goods and toys to more complex products used in automotive and aerospace functions.  No matter the purpose, all injection molded consumer products must first begin with a quality built injection mold produced with quality steel.  

As design engineers are aware, a quality part begins with a quality tool.  When designing a critical consumer product, involving an experienced mold builder early in the design phase of your project can reap big benefits in time saved developing superior products.  An experienced mold designer can utilize CAD/CAM software and simulation designs alerting a product development engineer of critical areas that may succumb to underfill or breakage.  

Michiana Global Mold is experienced with manufacturing precision tools for numerous consumer product applications including electronics, high end business furniture, skylight frames, appliance parts and assemblies and critical automotive parts.   We have vast experience producing plastic and rubber molds of any variation including:

• Cold Runner Molds
• Hot Runner Molds
• Insert Molds
• Collapsible Core Molds
• Unscrewing Molds
• Stack Molds
• Shuttle Molds
• High-volume Production Molds
• Prototype Molds

Our skilled and experienced staff include expert designers with decades of experience designing complex, precision tools utilizing the latest in technological advancements with Unigraphics software, and mold flow analysis when required.   Our journeyman mold makers contribute to our more than 600 years of combined experience providing you with expert mold construction no matter the type or complexity of the tool.

We can provide you with early design consultation, expert mold construction and product sampling.  Tool status reports are provided upon request keeping your project on schedule.  Michiana Global Mold is a valuable addition to any supply chain, providing high performance, quality tools on time, and to your specification.

Michiana Global Mold has been producing high performance plastic and rubber molds used in a multitude of industries including consumer products, electronics and automotive since 1964. Contact us today to learn about our multi-tool discount and for a free design consultation.