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How are injection molds made?

The tools and products we use in our daily life, from the shells of machines to the screws and rivets, are all closely related to the moulds. The shape of the mold determines the shape of these products, and the processing quality and precision of the mold also determines the quality of the products. Because the size, specification and use of the products are different, the moulds used are also various. Broadly divided into: plastic mold and non-plastic mold two.

And non-plastic mold contains.

1, casting mold: faucet, etc.

2, forging mold: car body

3, die-casting mold: cylinder block

4, stamping mold: computer panel

Plastic moulds are divided into.

1, injection molding mold: TV casing

2, blow up mold: beverage bottles

3, compression molding mold: bakelite switches, scientific porcelain dishes

4, transfer molding mold: integrated circuit products

5, extrusion molding mold: glue tube, plastic bags

6, Thermoforming mold: plastic finished packaging shell

7, Rotational molding mold: soft rubber doll toys

This article let us focus on the injection molding mold.

Injection molding mold is mainly composed of multiple steel plates with various parts, basically divided into.

1, molding device

2, positioning device

3, fixed device

4, Cooling system

5, Constant temperature system

6, Flow channel system

7, Ejector system

The overall process of a new product mold opening is usually as follows.

1, 3D drawings, 2D drawings or product samples

Designing injection mold drawings, through the material properties, product feasibility analysis, such as wall thickness, deformation, mold flow, single cavity or multi-cavity, into the rubber position, etc., in advance to determine the potential problems, making the design reasonable

2, Choose the material of the mold

Plastic molding molds are usually made of hardened or pre-hardened steel, aluminum and/or beryllium copper alloy. Steel molds cost more, but are often favored due to their high durability. Hardened steel molds are heat treated after machining, and they are excellent in terms of wear resistance and longevity.

Many steel molds are designed to produce over 300,000 to 1,000,000 parts over their lifetime. For smaller volumes, pre-hardened steel molds offer a less abrasion resistant and less costly option.

Aluminum molds, on the other hand, can be significantly less expensive, but they are typically not suitable for high volume production or parts with narrow dimensional tolerances. However, when designed and manufactured using computer numerical control (CNC) machines or electric discharge machining (EDM) processes, aluminum molds can be economically produced in tens to hundreds of thousands of parts.

Copper alloy inserts are sometimes used in areas of the mold that require rapid heat dissipation. This reduces cycle time and improves the aesthetic quality of the part.

Stroller products Ride-ons are mostly made in hardened steel molds.

3, Preparation, Processing

The processing of plastic molds usually consists of

A,Grinding

B,Milling

C,Drilling.

D, CNC

E,Lathe

F,Grinder

G,Matching die

Match the concave die and convex die to see if the fit is tight and ensure the quality.

4,Assemble the mold

5,Make nameplate

6,Test mold

7,Production

8、Mold maintenance and repair

Cost

As for the mold cost of a set of stroller products, this depends on the size of the car, the complexity of the structure, high precision processing. Product quality requirements vary. Usually the cost of a plastic foot to floor toys mold is about 25000 USD or more.

Case Study: Using Plastic Injection Molds to Make Bath Toys

Recently, we had an entrepreneurial customer come to us with an idea for a plastic part. He had been in the mother and baby industry for many years and wanted to design his own exclusively designed bath toys. However, he needed to scale up his production to meet the daily demand volume. He contacted our ZHXTOYS team to see if plastic injection molding would be a good fit for his design.

After viewing the hand-made prototype, we suggested him to open a small mold for the following reasons.

The plastic part was less than 40g.

The customer needed to produce more than 1000 plastic parts per year.

The plastic parts have uniform wall thickness.

The plastic parts could be made from thermoplastic materials.

We could design a mold for him, make a hand board, machine the mold, try out the mold, and start production in just a few months. Most importantly, we will keep his design confidential and respect the original design by reminding the customer to apply for a patent.

Today, the client purchases thousands of pieces per year and the number of orders for his bath toys is steadily climbing.

Check out our other case studies to see how this process worked for you:.

design molds and provide sound mold input

Opening molds on your behalf

Maintaining the molds

What does an injection molding manufacturer do?

Injection molders have a wide range of capabilities and services. Some companies use only pre-existing designs, while others provide support throughout the product development process.

As a full-service plastic injection molding manufacturer, ZHXTOYS offers a full range of mold making and production capabilities. From consulting to product distribution, our customers benefit from our long list of in-house capabilities, including

Part design

Hand Board Fabrication

Mold design

Mold manufacturing

Injection molding production

Pad Printing

Packaging

Inspection

ZHXTOYS is a second generation family owned and operated full service plastic injection molding contract manufacturer. We are based in China and work with large companies and start-ups around the world. Contact us today to find out if this process is right for your idea or company. You can also submit an online quote for your injection mold.

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