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Design and Manufacturing of Injection Molds

Design and Manufacturing of Injection Molds  Injection molding is the most common method of plastic processing. It is used for manufacturing a wide range of parts for a variety purposes and applications. The injection mold is the most important part of the molding technology. The appearance, accuracy of the dimensions, reliability and productivity of the plastic parts depends on design and quality of the mold. But no less important are the characteristics of the injection mold as its production resource, simplicity in routine maintenance. The cost of ordering high-quality molds is more than compensated for during their life time: equipment downtime is minimized, energy and funds are not being spent for repairs and debugging, casting products are positioned at a better level than competitor's. We have many years of experience in designing and manufacturing injection molds for the following product groups:
  1. PET preforms;
  2. Covers, caps, lids, valves, handles for carrying, auxiliary decorative elements;
  3. Disposable cutlery;
  4. Plastic parts for build finishing and remodeling;
  5. Stationery articles;
  6. Casing products.

Mold for PET preform 32 gramm Mold for canister cap

Mold for cosmetic cap Mold for 1.8 l bottle handler

Mold for 5 l bottle cap Mold for forks

Mold for body of electric counter Mold for stationary tray

Mold for auto splash guard Mold for baboon

Mold for Christmass tree holderWe design and manufacture injection molds considering specifics of the developed parts models, optimally working on certain types of injection molding machines. For a while place order for mold onpur company (PTL), it is not necessary to have ready drawings, 3D-models or complete set of tech. documentation of the desired product, although it highly appreciated. A pencil sketch, photo or physical sample of expected final plastic product is good enough for project start. Our designers will develop 3D models for the final product as well as (latter) technical documentation for the mold. They also advice how to optimize design, improve processability, select correct type/supplier of raw materials. It is also possible to develop products that do not have any analogues or prototypes, to say: "scratch project", incl. cooperation with third-party organizations (as art studios, etc.).

When the first stage is over, the customer agrees virtual 3D images and flat drawings of the product. If necessary, the customer may print 3D-prototype of the plastic by the it's 3D model e-mailed by us in STL format.

Example of agree of 5l PET bottle capAfter agreeing the product, our designers begin to design the mold. At this stage, we take into consideration the preferences of customer for the materials use: steels types, ready bought parts brands, heat treatment type & hardness etc. (see also section Stages of mold manufacturing). All of details to be written down and issue moldmaking declaration signed by both of parties.

After mould completely designed, we turn to it's manufacturing. For more information about our moldmaking technology, please refer to: our metal processing shop facilities overview.

After the mold is manufactured we do comprehensive it's testing:
- working tests: e.g. check a cooling system, the smooth operation, ejection system effectivity, correct discharge of molded parts, and so on;
- product tests: casting defects (if it happen), the geometric dimensions, roughness of surfaces, common impression.
Samples of parts to be sent to the customer. After testing the samples, the customer (if necessary), fills (signs) the remarks list. We made final finishing of the mold and get samples again. If necessary we repeat mold refinement and testing. After all of this steps mold could be supplied to customer. © PTL

See also the photos of PTL STUDIO ©.

Designing PET preforms and hot runner molds for their production

Only at first glance, all the preforms are similar to each other differing only in weight and neck connectivity (screw thread standard). However, this is far from true. The success of the each bottle is hidden in the preform design. Ideally, for each shape and bottle size, there must be a unique design of the preform. Because of the many inconsistencies between the shapes of the bottle and the preform, it is usually difficult to blow out the ideal bottle. Correctly matching the designs of the bottle and the preform, it is possible to obtain a better bottle from a preform with a much smaller mass due to a more optimal distribution of wall thicknesses and the geometry. The economy is obvious.

In recent years, the PET packaging market has significantly changed. The needs for a variety of bottles, cans, PET containers for new market applications is highly increased. There are many decorative elements required as usual. A new important critical demand of the market is a decrease in the material consumption and the cost of packaging. Characteristically, it is necessary to blow the bottle of a larger volume and a much more complex shape from preforms of lower weight than it was ever before. Often we have to work near the limit of the PET material physical blow capabilities. The requirements for the geometry of preform body (mass distribution and different thickness) become more and more complex.

In addition to traditional applications ( water, drinks, vegetable oils, beer), PET packaging has been widely used in the last decade for bottling and packaging of dairy products, juices, a variety of food products, household chemicals, perfumes and pharmaceuticals. The specificity of filling viscous or loose products on one side and the requirements of a high style (for example, for cosmetics and perfumery) requires a fundamentally new approach to the design of bottles and, consequently, preforms for it's optimal blowing. We have a continuous 20-year design experience of preforms and manufacturing preform molds.

Recently, we have fulfilled many orders for the manufacture of molds for the molding of preforms produced from resycled PET resins (polymers), which imposes a number of additional requirements on the hot runner system.

Designing closures (caps, lids) and molds for their production

There are depends a lot of the quality of caps, covers, their ergonomics and reliability. Is highly important not only to successful model the cork design, but also to make the cork cheap, not too sensitive to deviations of molding technology, long-term wear of injection molds and use of cheap (and often not very high quality) raw materials.

In addition, there are quite a lot of requirements for such products from end users, cappers, traders, certification authorities, sanitary inspection, etc. Of closures reliability depends on the safety of the products, "shelf life", etc.

Therefore, it is necessary to take seriously developing new of closure products, as well as injection molds, to which we have been paying a lot of time and energy for more than 20 years.

Designing of disposable cutlery and molds for their production

The most significant requirement for the massive use disposable cutlery is the cost reduction. Lowering the cost price can be achieved by reducing the weight and reducing it's molding cycle.

The products should be designed in such a way that the minimum weight ensures the molding ability of plastic in the mold and satisfies the requirements for mechanical strength (stiffness) of products, their group packaging, the absence of micro-cuts on the working edge surfaces. The struggle is already gone for saving hundredths of a gram for each unit.

Due to the mass-batch nature of the production of disposable cutlery, the approaches used to design injection molds differ than for any other less batch products. Molds for disposable cutlery should withstand several (or dozens of) times more cycles of mold clamping, and this requires fundamentally new approaches to the design and manufacture of injection molds. We have manufactured more than a hundred such molds for forks, spoons, knives and stirrers and we have the great experience in this field.

Designing of stationery and molds for their production

The key to success in the design of stationery products - a good look, ergonomics, functionality of use.
In addition, many requirements are imposed on the quality of production, front view surfaces appearance, as well as to reduce the cost of production due to the great competition in the market.

The design and manufacture of injection molds requires specific approaches, because products often have large surface areas with sufficiently thin walls, which, when cast, leads to extremely high loads on the mold. In order to avoid the appearance of dynamic and static deformations that ultimately lead to the failing the mold, the structure of the mold should include the special reinforcing elements for strengthening and compensating the loads.

We have 15 years of experience in this field, many of our forms for stationery have been in operation for more than 12 years.

Designing build finishing and remodeling & injection molds for their production

An important part of the specifics of such products is the provision of an impeccable appearance, functionality and compatibility with the response parts, which is important for increasing the performance of installation works and preventing their improper location.

In addition, the surfaces of products should allow easy applying decorative coatings (images) that mimic natural textures.

The presence of a large number of thin delicate joining elements of the products impose demands on the reliability of the mold parts, which accordingly must reflect this "fineness" and "delicacy". We designed and manufactured dozens of molds for this market field.

Designing of plastic case products and injection molds for their production

The specifics and varieties of case products are wide and multifaceted.

For each case, a separate elaboration of the through product design is needed, including an obligatory check of the connectivity with the electrical / electronic stuffing and any of it's response parts.

To verify the results of the design, it is usually required to use 3D printing to obtain prototypes and verify the interoperability and functionality. We transfer to customers a model for 3D printing in STL format, or we print the products ourselves and transfer them to the customer for evaluation and comments before start new mold project.

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