When companies are smart enough to take advantage of the expertise of their molding partners, the result is to have the most effectively molded parts possible.
There are many nuances and intricacies in the process of creating precision injection molded components. These fine details and comprehensions are best addressed by those who deal with them daily.
When presented with the challenge of producing medical parts, for instance, numerous designs and production issues such as aesthetics, design-function or maximized-optimization all need to be addressed.
Overcoming Intricacies: Medical Molding through Collaboration
All part designs must be mold-able. The mold and process must be well planned. Molding processes must incorporate very high levels of precision.
These are important considerations for any quality product emerging from any industry. Yet medical parts demand the highest available levels of expertise.
Poor designs create product flaws that present significant safety concerns. All weak-links in design or fabrication processes totally compromise the integrity of the final part - while leading to expensive redesign.
Collaborative efforts are the most effective approach for all involved parties to safely guarantee the parts are of the best design for ease-of-manufacture-ability.
To this end, designers should always rely on all expertise available from both mold-making partners and molding partners alike.
Highest Quality Parts and Design Emerge from Expert Cooperation
The most successful precision injection molded components are produced when the part designer, manufacturer and tool designer have all come together to offer ideas and input from the earliest possible stages of development.
Through this active, constant cooperation--any team of precision injection molded component designers can avoid the common molding snags and produce more efficient and cost-effective parts.
Confirm All Part Designs and Materials
The starting point for all quality production of finished pieces is part design. This drives the whole development process while setting the course for your precision injection molded components from mold design through production.
The specific features of any part’s design will hinder the tool-building and molding stages if not completely comprehended early-on in collaboration:
• Wall Thickness: consistent wall thickness within all part design minimizes the following imperfections:
• Sink Marks: these slight dips show up in the surface of your part. They are common part imperfections from insufficient packing and inconsistent wall thickness.
• Warp: this is also a distortion to the part's surface. A sink may be localized, yet a warp can effect the whole part. Inconsistent wall sections and thickness causing temperature variations while cooling are the cause.
• Voids: these are internal imperfections. They occur most often in thick-walled areas of the part. They happen when a significant difference in cooling rates between skin and core material have occurred.
• Durability: it's important to consider the durability of the part on ejection from any mold. Avoid incorporating delicate, fragile features that have a tendency to break during the ejection process.
• Gating: part designers also need to understand nuances of gating design. The part needs to have gate vestige for determining best placement. Gates are best when placed at the thickest part area so the plastic will flow naturally into thinner areas.
• Material Selection: some materials will fill out thicknesses better than others. Some have more uniform shrinking than do others. This reality influences the final part integrity. Advice on material properties makes or breaks the flow results within the precision injection molded components.
• Mold Design / Fabrication: your mold maker is usually the one driving your mold design processes. They should already know to work closely with your molder and your part designer. Teamwork is the key to high quality design to function processes. Software is used to lead to perfected CAD designs.
Mold-ability and Mold Steel
A great mold design comes from a mold maker who first ensures the part design is physically moldable. Occasionally it happens that a designed part can’t be molded. To avoid this, become certain the steel can be fabricated according to the precision injection molded component's design.
The steel behaves differently during fabrication than what is typically assumed during design. Designers depend on the steel being thick enough to withstand the injection process. This is where wall support comes in. Avoid flash and excessive reoccurring maintenance costs.
Over time, every mold will wear out. The best tool designers can evaluate which parts of the mold will wear out most quickly. Great tool designers will build spare parts to head-off difficulty such as production delays.
Why Partner with Crescent Industries
Crescent Industries is an employee-owned organization that has been setting standards for precision injection molded components production for decades. Partnering with industry experts is the best way to head-off complications, losses and other reputation-critical events. For more partnering information simply contact us by phone 1-800-411-3844 or visit our website www.crescentind.com.