Your #1 Mold manufacturer

Wire EDM

Advantage of Mold Manufacturing

  • Outstanding Design Team for Export Molds
  • Rich Experience Manufacturing Team
  • Up to Date Equipment
  • Quality Guarantee with ISO 9001:2015
  • Fast Delivery Time
  • Excellent After-sales service

Injection Mold Types

Insert-injection-part Insert injection partsFor insert injection molding, you need to put the inserts into the mold/tooling, then inject plastic material around it. The inserts can be steel, brass, ceramics, etc., and the external materials are plastic.

Insert injection molds are used for electronic connectors, auto parts, medical parts, and so on.

Insert injection molding is the injection molding of plastic and metal materials or several other materials into a product.

The main function of this forming process is to improve the wear resistance, impact resistance, fatigue resistance, electrical conductivity, and reduce the weight of the product.

Gas Assist injection mold Gas Assist injection mold

Gas-assist injection molding is the processing of using nitrogen to form hollows in plastic products.

First, the melting plastic is injected into the mold or tooling. When the plastic reaches 70% to 80%, the pressurized nitrogen is injected into the mold or tooling to push the melting plastic to the terminal of the product, thus forming hollows in the product.

The pressurized nitrogen is kept until the product cools and solidifies, thus forming hollows products.

The gas-assisted injection molding has the following advantage: reducing shrinkage marks, eliminating deformation, and reducing internal stress.

For engineering products, it can increase rigidity and strength. Moreover, the gas-assisted injection molding can reduce the tonnage of the injection molding machine, molding cycle time, and product weight, thus reducing product cost.

2K injection mold 2K injection mold

The 2k injection molding is a kind of molding process that several types of materials are injected into the same set of mold and several materials are used to form injection molded parts.

2K injection molding on one set machine that performs injection twice in a cycle.

In the first cycle, the nozzle injects the plastic into the mold. Then, the mold automatically rotates 180 degrees, injecting different types of plastics into the mold from the second nozzle, to make several kinds of materials in one cycle. This process is called 2K injection molding, which requires a special 2K injection molding machine.

2K injection molding optimizes the fusion of hard material and soft material, makes the product have many advantages, Such as makes the appearance of the product more beautiful, better performance, so then increases the market value of the product.

In Mold Decoration In Mold Decoration

In-mold decoration (IMD) is a kind of economic and durable processing technology of plastic product decoration. In-mold decoration (IMD) is to put the decorative film into the mold and then inject molten plastic into a mold to produce plastic products with exterior decoration.

The products with complete decoration, it does not need secondary processing. This process is divided into four steps: film printed, film thermo-formed, Trimming, and injection molding.

The processing is as follows: 1. Print the film according to the customer’s design; 2. Then thermo-formed the film on the aluminum tool. 3. Trim the shaped film to the required size; 4. Put the shaped film into the injection mold for molding, get a complete decorated product. The most typical In-mold decoration (IMD) is used in automobile and electronic products.

Micro Injection mold Micro Injection moldMicro-injection molding, commonly known as micro-molding, is a special molding process used to produce products with overall size in millimeters, or functional features and tolerances in millimeters or even microns.

This microfeature of the product requires special molding equipment and corresponding auxiliary equipment to complete injection molding, as well as special mold insert and cavity development technology.

The traditional machining methods such as various machining methods and EDM (EDM) can be used in the machining of micro-injection molds. However, with the reduction of mold insert and cavity size, the traditional methods quickly reached their processing limit. Some technologies in the field of microelectronics have been used in the manufacture of micro-injection mold inserts and cavities.

One common method is LIGA, which is an acronym for German words copied by x-ray deep lithography, electroforming (electroplating), and injection molding. Other processes include micro-cutting, ultra-precision machining, laser processing, and micro-EDM technology.

Thin-wall-mold Thin-wall-moldWhen the wall thickness of the product is less than 1mm that called Thin Wall Injection Molding. More scientific explanation, the definition of a thin wall is related to the flow/wall thickness ratio.

The flow line of the mainstream from mold to finished product is divided by thickness T of the finished product called flow/wall thickness ratio. When L / t > 150, it is called a thin wall. If the thickness of flow is inconsistent, can be divided into the calculation.

Forming thin-wall products requires a special design of thin-wall product molds. Compared with the standardized mold of conventional products, the mold of thin-wall products is quite different from the mold design, Injection system, cooling system, venting system, and demoulding system.

The injection molding machine used in the thin-walled plastic parts is also different from the conventional injection molding machine. Because the filling time of thin-wall injection molding is very short, and many filling time is less than 0.5s, it is impossible to follow the velocity curve or cut-off pressure in such a short time, so it is necessary to use a high-resolution microprocessor to control the injection molding machine; During injection molding process of thin-walled products, the injection pressure and speed require independent control simultaneously.

If the thin-wall injection molding material is to have good fluidity, it must have a large flow length. It also has high impact strength, high thermal deformation temperature, and good dimensional stability.

 

Unscrewing injection mold Unscrewing injection moldInternal threads often appear on plastic products such as caps, lids, and plastic hardware. Because thread easily damaged natural attributes, injection molding thread product is a little different compare with molding ordinary plastic parts. The unscrewing core requires automatic pull off from the plastic part without damaging thread.

Usually, the threads of plastic parts are automatically threaded through rack and gear, and collapsible cores are also used for unscrew threads. For unscrewing structure, our company mainly uses hydraulic cylinder drive, servo motor drive, hydraulic motor drive, worm wheel rod drive.

Plastic parts with the threaded injection molding process.
The first mold closed plastic material entering the mold cavity, after holding pressure and cooling, the automatic unscrewing system starts work, hydraulic cylinder drive rack and gear, unscrew cores rotating backward and out of plastic parts. Mold opening, ejection system works, and eject out plastic parts. After the ejection system finished the work, the hydraulic cylinder reverse movement back in the original position. The unscrew system back to the molding position, then into the next injection molding cycle.

Collapsible Core mold

Collapsible Core mold

The collapsible core can enlarge the ability of undercut shaped more than any other solution. In the normal mold sequence, the function of flexing steel collapsible cores is to fold in radially, instead of force demould the thread or unscrewing mechanical thread.

They eliminate secondary operation and complex coring methods and provide significant cycle time reduction, usually 30% faster than the unscrewing mechanism.

The petals of the collapsible core are connected with the ejector plate, while its center angular conical pin is connected with the bottom of the mold. During the mold opens, the undercut outer core moving toward to inside when the ejector plate moving away. Only three moving parts utilize traditional mold movements, a collapsible core that makes parts designed previously considered impossible to be molded.

The collapsible core is a good solution to remove injection parts with undercuts or threaded parts from the mold cost efficiency.

Our collapsible core molds incorporate only three moving parts, which use more ordinary mold movements. Because of this blending of technologies, collapsible core molds enable part designs that would have previously been considered impossible, now moldable.

Prototype mold Prototype mold

Prototype molding plays a key role in the plastic injection molding product development process.

In almost every product development instance whatever industry it is a prototype is a necessary stage ultimately determining whether your production effort is successful. Prototyping molding makes fast plastic prototypes easier and affordable. Prototyping technology can help detect product design flaws and other problems, saving time and money.

Prototype molding can quickly produce products to shorten your development time. Prototypes molded parts can be used for painting and decoration, as well as final products, allowing your products to quickly enter markets.

With more than 20 years of experience in providing prototypes molding, Kemal will work with you together with you for your project.

Finishing

 

SPI A is mirror polishing.

SPI A Glass inludes SPI A0, SPI A1,SPI A2,SPI A3. The detail is followed:

SPI A0:  grade #1 diamond buff.

SPI A1:  grade #3 diamond buff.

SPI A2:  grade #6 diamond buff.

SPI A3:  grade #15 diamond buff.

SPI B is Sand paper polishing.

SPI B1:  #600 grit Paper.

SPI B2:  #400 grit Paper.

SPI B3:  #320 grit Paper.

SPI C is Stone paper polishing.

SPI C1:  #600 Stone.

SPI C2:  #400 Stone.

SPI C3:  #320 Stone.

SPI D is Sand blasting.

SPI D1:  dry blast glass bead #11.

SPI D2:  dry blast #240 oxide

SPI D3:  dry blast #24 oxide

Charmills VID 3400 or Sodick

MoldTech and YS.

It is machined by CNC milling, lathe machining, Grinding machining.

Application

Aerospace
Automotive
Medical
Consumer Products
Zeeltronic
Industrial
Energy
Furniture

Injection Mold Cases

  • Stack mold
    Stack mold
  • Stack mold
    Stack mold
  • Medical Syringe mold
    Medical Syringe mold
  • Medical Syringe mold
    Medical Syringe mold
  • Medical Tip mold
    Medical Tip mold
  • Medical mold
    Medical mold
  • Medical mold
    Medical mold
  • Gear mold
    Gear mold
  • Medical mold
    Medical mold
  • Medical mold
    Medical mold
  • Auto mirror cover
    Auto mirror cover
  • Door panel
    Door panel
  • bumper-mold
    Bumper mold
  • Bump-mold
    Bump mold
  • Bump mold
    Bump mold

Kemal Your Mold manufacturing Expert

Kemal Mould was established in 1995, and specializes in plastic injection molds building for all the customers around the world.

Kemal Mould occupies about 6500 square meters, with more than 180 staff, including 39 experienced engineers, 80 skilled tool makers. HASCO, DME & LKM standards are adopted for different customer requirements, and CAD/CAM/CAE systems have already been used to strengthen our technical advantage.

During 25 years of development, Kemal Mould has set its own mold standards and strict mold manufacturing process. Each mold is run as project management, followed up by particularly experienced engineer. 6S management system has been adopted for many years. Kemal mould is also ISO9001:2015 certified.

By maintaining the sound quality, best lead time, and good services, Kemal mould has established long-term business cooperation with customers from Germany, USA, UK, France, Israel, Australia, Canada, Russia, and other countries.

FAQs

Send Your Inquiry Today

MOLD MANUFACTURING: THE ULTIMATE FAQ GUIDE

As a professional mold manufacturing supplier, Kemal makes 550 sets of molds per year. And we have been trying our best to satisfy our customers’ requirements since 1995. That is why we have prepared this guide for you. Trust that you can obtain most of your queries and our company from it. If you find anything we can do to support you, please be free to contact us. We are available 24/7/365.

  • What’s the process for Mold Manufacturing?
  • Which machines are used for Mold Manufacturing in Kemal?
  • How many types of surface treatment for Mold Manufacturing?
  • What is the common steel for Injection Mold Manufacturing?
  • What’s the standard for American mold base in Mold Manufacturing?
  • What are the standards for polishing of Mold Manufacturing?
  • What are Kemal’s capacity and advantage for Mold Manufacturing?
  • How does Kemal control quality during Mold Manufacturing?
  • What are the advantages of Mold Manufacturing by Kemal?
  • What is Standardization of Mold Manufacturing?
  • What is the meaning of Mold Manufacturing Standardization?
  • How many types for Mold Manufacturing?
  • As one of the types of mold manufacturing, what are the advantages of Prototype Tooling (RT)?
  • What is the basic requirement for Mold Manufacturing?
  • What are the characteristics of Mold Manufacturing?
  • What are the advantages of Arc spraying Mold Manufacturing Technology?
  • What is the common heat treatment technology for Mold Manufacturing?
  • What is 3D Printing in Mold Manufacturing?
  • What are the advantages of 3D Printing of Mold Manufacturing applications?
  • What is Reverse Engineering in Mold Manufacturing?

 

Q1. What’s the process for Mold Manufacturing?

For mold manufacturing, here is the complete process for your reference.
DFM Report – Mold Design – Material Preparation – Processing – Mold Base processing – Electrodes Processing – Mold parts Processing – Quality Control – Mold Fitting & Assembly – Inspection – Mold Trial – Mass Production.

Automotive Door Panel mold design, Mold Manufacturer, Mold maker

Q2. Which machines are used for Mold Manufacturing in Kemal?

Our mold workshop covers an area of about 4200 square meters, equipped with more 70 machines of high precision and 80 technicians of over 10 years’ experience in mold manufacturing.
For mold manufacturing, Kemal uses CNC milling machines, CNC for electrodes, precision wire-cut machines, mirror EDM machines, wire-cut machines, EDM machines, small hold EDM drill, manual milling machines, grinding machines, rocker driller, gun drilling machine, lathe, spotting machine, saw machine, CMM, and optical projector, etc.

CNC Machine-Mold Manufacturing

CNC Machine-Mold Manufacturing

CNC Machine-Mold Manufacturing

Wire-cut-EDM Machine-Mold Manufacturing

EDM Machine-Mold Manufacturing

EDM Machine-Mold Manufacturing

Q3. How many types of surface treatment for Mold Manufacturing?

Here are 5 common types of surface treatment for Mold Manufacturing.
1.Polish
Polishing means the use of mechanical, chemical, or electrochemical effects to reduce the surface roughness of the workpiece to obtain a bright and smooth surface. It uses polishing tools and abrasive particles or other polishing media to modify the surface of the workpiece.

2.Thin Fire Texture
After EDM machining, the texture is left on the plastic injection mold. Because the cost is relatively high, the thin fire texture processed by the electrode is seldom used.

3.Texture
The texture has the advantage of low processing cost, rich effects, and fast speed.

4.Plating
It is the process of using electrolysis to deposit metal or alloy on the surface of the workpiece to form a uniform, dense, and good bonding metal layer.

5.Sand Blasting
Sandblasting is a process for surface treatment of workpieces. Compressed air is used as the power to form a high-speed jet beam to spray the spray material on the surface of the workpiece to be treated at a high speed so that the appearance or shape of the workpiece surface is changed.

Q4. What is the common steel for Injection Mold Manufacturing?

1.C45W (Medium Carbon Steel)
American Standard #: AISI 1050 ~ 1055; Japanese Standard #: S50C ~ S55C German Standard #: 1.1730.

2.40 Cr Mn Mo 7 (Pre-hardened plastic mold steel)
The United States, Japan, Singapore, Hong Kong, China standard code is AISI P20, while Germany and some European countries Code is DIN: 1.2311, 1.2378, 1.2312.

3.X 40 Cr Mo V51 (Hot work Steel)
The standard code for America, China, Hong Kong, Singapore is AISI H13; for Europe is DIN 1.2344, and for Japan is SKD61.

4.X45 Ni Cr Mo 4 (Cold work steel)
The standard code for America, China, Hong Kong, Singapore is AISI 6F7, and the European number is DIN 1.2767.

5.X42 Cr 13 (Stainless steel)
The standard code for America, China, Hong Kong, Singapore is AISI 420 STAVAX while for Europe is DIN 1.2083.

6.X 36 Cr Mo 17 (Pre-hardened stainless steel)
The standard code and European code are AISI 420 STAVAX and DIN 1.2316 respectively.

7.X 38 Cr Mo 51 (Hot work steel)
The standard code and European codes are AISI H11 and DIN 1.2343 respectively.

8.S 7 heavy-duty tool steel
This steel is usually used by American customers.

9.X 155 Crvmo 121 Cold Work Steel
The standard code is AISI D2. And the European code is DIN 1.2379, while for Japanese code is JIS SKD11.

10.100 Mn Cr W4 & 90 Mn Cr V 8 (Oil steel)
They are AISI 01& AISI 02 for the standard code, and DIN 1.2510 & DIN 1.2842 for the European code.

11.BeCu
This material is generally used in places where it is difficult for cooling in plastic molds because copper has a much faster heat dissipation effect than steel.

Q5. What’s the standard for American mold base in Mold Manufacturing?

Steel standards for American mold bases:
1.1#1: All the templates use AISI 1050, the hardness is 13~18 HRC.

1.2#2: AISI P-20 for all templates, except square iron and thimble plate. And the hardness is 28~32 HRC. Strength is 900N/mm2.

1.3#3: A and B templates are improved with AISI P-20, with the hardness of 32~36 HRC, and they can be used as high polishing and spark erosion steel.

1.4 #7: Pre-hardened AISI 420H is suggested for A, B plate and the plates with cooling, and the hardness is 33~37 HRC (strength 915~1200N/mm2). Others should use the same standard as #2.

1.5 If the mold base must be equipped with a hot runner, the template for the hot runner can be #1 steel (AISI 1050), and the rest of the template is still based on its original standard.

Q6. What are the standards for polishing of Mold Manufacturing?

1.Before the mold trial, we should check whether the polishing is qualified or completely finished.

2.Besides, we should check whether the EDM texture is correct and it can be demolded or not.

3. For mirror polishing, the steel must be ASSAB 136, with a hardness of 52-54HRC. (High tempering temperature is required, and it is best to use a vacuum furnace for doing so.)

Q7. What are Kemal’s capacity and advantage for Mold Manufacturing?

Kemal can manufacture 550 sets of molds per year for our customers all over the world. And we have a comprehensive set of state of the are mold manufacturing machines. We have 1 MAKINO & 1 MIKRON CNC milling machine, with a high precision of ±0.002. Besides, we have 4 precision wire-cut machines (SODICK) made by Japan, with a precision of ±0.003. As for mirror EDM machines, we have 2 CHARMILLES, 2 SODICK, and 2 MirrorDick with ±0.002 precision. Moreover, we have 13 CNC machines for steel processing only, while 5 CNC machines for electrodes. We separate the CNC machines into 2 different workshops, so the machines can be protected against dirty or damage.

Q8. How does Kemal control quality during Mold Manufacturing?

With ISO9001 certificated, Kemal always puts quality in the first place. To meet customer’s requirements and expectations, we manage the quality of tooling and goods by the advanced measurement facilities, under the advanced and complete quality control system, with the scientific methods of quality control.
During mold manufacturing, Kemal will do the In-coming Material Inspection and Manufacturing Process Inspection.
In-coming Material Inspection
Perfect material analyzing laboratory will ensure all the materials are in compliance with international standards and European environmental protection requirements. Kemal uses the CMM for dimensions inspection.

Manufacturing Process Inspection
All-round implement advanced quality control methods such as CPK, SPC, Quality Management Circle, etc.

CMM for Mold Manufacturing

CMM for Mold Manufacturing

Hardness Tester & Optical Projector for Mold Manufacturing

QC Equipments for Mold Manufacturing

CMM for Mold Manufacturing

Q9. What are the advantages of Mold Manufacturing by Kemal?

Firstly, Kemal has several high-precision mold manufacturing equipment, like MAKINO & MIKRON CNC milling machines, SODICK wire-cut machines, and mirror EDM machines (CHARMILLES, SODICK, and MirrorDick), etc.
Secondly, Kemal has a complete quality control system, includes In-coming Material Inspection, Manufacturing Process Inspection, and Finished Products Inspection.
Lastly, Kemal offers excellent After-sales Services. If our customer has any questions about their molds (no matter the molds made by Kemal or not), we can support them 365/24/7. And if needed, we can fly to our customer’s factory to provide our support. Furthermore, Kemal’s engineering team can give staff training to our customers.

Q10. What is Standardization of Mold Manufacturing?

During the mold manufacturing process, the use of mold standardization for production is a comprehensive technical work to develop mold production technology. The so-called standardization of molds manufacturing means that the shapes and sizes of many parts of the mold, as well as various typical combinations and typical structures, are implemented in a unified structure form and size, and standardized series are implemented, and specialized production is organized to better satisfy users’ selection. Mold manufacturing standardization involves all aspects of mold production technology, including mold design, manufacturing, materials, acceptance, and use.

Q11. What is the meaning of Mold Manufacturing Standardization?

Mold manufacturing standardization is the backbone of the mold industry, the most effective means to improve the economic efficiency of the mold industry, as well as the basis for the adoption of specialized and modern production technology. The main significance of realizing standardized in mold manufacturing lies in:
1.Mold manufacturing standards are the basis of mold production. This is because mold manufacturing standardization is the process of formulating and revising mold standards and implementing mold standards. The mold manufacturing standard has been formulated and widely implemented and used. Only then can we organize specialized production according to the standard and obtain high economic benefits.

2.Mold manufacturing standardization is the fundamental way to improve mold manufacturing quality, increase productivity, shorten the mold manufacturing cycle, and reduce production costs. Generally speaking, professionally produced mold standard parts have the advantages of reliable quality, high precision, and low cost. Standard mold parts are widely used in mold manufacturing, which can greatly improve mold manufacturing quality. At the same time, the mold manufacturing cycle can be shortened by 20% to 40%, and the mold cost can be reduced by more than 20% to 30%.

3.Mold manufacturing standardization is a prerequisite for developing computer-aided design and manufacturing (CAD/CAM) of molds. In-mold production, the use of CAD/CAM technology to produce molds can ensure and improve the accuracy and quality of the mold, and can greatly reduce the cost of mold manufacturing. It is the only way to change the backward situation of mold production. However, to realize CAD/CAM production technology, it must be matched by standardization of molds, that is, from the drawing rules of mold drawings, simple drawing methods of graphics, standard mold bases, typical structural design parameters, part shapes and structures, and process requirements. Corresponding standards, otherwise the CAD/CAM work of the mold is difficult to achieve.

4.The standardization of mold manufacturing can promote international technical exchanges and cooperation, which is conducive to strengthening the competitiveness of molds in international trade and is conducive to the expansion of mold exports to earn foreign exchange.

Q12. How many types for Mold Manufacturing?

There are various types of molds for mold manufacturing. And the most common types are 2 plate mold, 3 plate mold/pin-point gate mold, hot runner manifold mold, thoroughly harden mold, and pre-hardened mold.
1)The two-platen mold, also known as the single parting surface mold, is the simplest type of injection mold. It divides the entire mold into two parts based on the parting surface: Moving mold and fixed mold. Part of the cavity is in the moving mold; part of the cavity is in the fixed mold. The main runner is in the fixed mold; the runner is located on the parting surface. After the mold is opened, the product and the runner remain in the moving mold, and the moving mold Some have an ejection system. Here is an image for your reference.

2)There are two parting surfaces that divide the mold into three parts, and a gate plate is added to the two-plate mold. This kind of mold uses a pointed gate, so it is called a pin-point gate mold.

3)With the help of a heating device, the plastic in the injection system will not solidify and will not be demolded with the product, so it is also called a non-runner mold.

4)The steel used in the inner mold part needs to be heat treated (such as quenching) after being purchased to meet the requirements of use, such an injection mold is called a hard mold.

5)The steel used in the inner mold part does not need to be heat-treated after purchasing, and it can meet the requirements of use. Such an injection mold is called a soft mold.

Q13. As one of the types of mold manufacturing, what are the advantages of Prototype Tooling (RT)?

The notable features of RT are short molding cycle, simple process, easy promotion, low molding cost, precision, and life span that can meet specific functional requirements, and comprehensive economic benefits are good enough. It is especially suitable for new product development, process verification and function verification, and small batch production of multiple varieties. At present, RT has been widely used in the automobile, aerospace, military, electronics, medicine, home appliances industries, and so on.

Q14. What is the basic requirement for Mold Manufacturing?

The basic requirement of mold manufacturing is to shorten the molding cycle and reduce mold costs as much as possible on the premise that the accuracy and life of the mold meet customer requirements.
The technical and economic indicators of the mold include mold accuracy, mold production cycle, mold production cost, and mold life. In the mold manufacturing process, the following four technical and economic indicators should be considered comprehensively:
High manufacturing accuracy
Short manufacturing cycle
Long service life
Low manufacturing cost
The four technical and economic indicators of the mold influence and restrict each other, and must be considered comprehensively to obtain the best economic benefits and meet production needs.

Q15. What are the characteristics of Mold Manufacturing?

There are several characteristics of mold manufacturing. Here are some of them for your information.
1.Mold manufacturing belongs to single-piece, multi-variety production. Each mold can only produce a single product, and the mold is generally not universal.

2.Customers require a short mold manufacturing cycle.

3.Complete set of mold manufacturing.

4.The precision of the mold is high, and the precision depends on the precision of the machine tool, processing technology, and measurement methods.

5.In the mold manufacturing process arrangement, the process is relatively concentrated to ensure the quality and progress of mold processing, simplify management, and reduce process turnaround time.

6.Mold working parts have complex shapes, high material hardness, heat treatment needs to be arranged in the mold manufacturing process.

Q16. What are the advantages of Arc spraying Mold Manufacturing Technology?

Arc spraying mold manufacturing technology has the following advantages: (1) No matter the material of the original mold is metal, wood, or plastic products, the resulting mold cavity has a clear outline and the shape and dimensions remain unchanged. The size remains the same, because the surface temperature of the original mold during spraying generally does not exceed 60℃, and there is no problem of thermal stress and deformation. (2) The mold-making efficiency is high, and the size is unlimited, and it can be as small as the size of a coin or as large as a vacuum forming mold for the inner roof of an automobile. (3) The equipment investment is small and the economic benefit is good. The plastic production line can quickly change the product variety to meet the changing requirements of the market. (4) It can better save the total cost. Compared with other ways, this way can save 2-20 times the cost.

Q17. What is the common heat treatment technology for Mold Manufacturing?

According to the working conditions of the mold manufacturing, the mold can be divided into two types: cold work mold and hot work mold, and the heat treatment process is slightly different.
1.Cold work dies: It requires high hardness, high wear resistance, and certain toughness, so this type of die steel often contains high carbon content. Therefore, pre-heat treatment after forging and final heat treatment after machining is required. The usual heat treatment process is Spheroidizing annealing, quenching + low-temperature tempering, sometimes chemical heat treatment is required, such as carburizing, nitriding, carbonitriding, etc., surface quenching, stress relief annealing, and individual precision molds also need to be stabilized tempering or supplementary tempering.

2. Hot working die: Since the processing object is often the steel heated to the austenitic state, it needs a certain degree of hardness and high wear resistance. Due to forging, it needs high impact toughness. Therefore, this type of steel is often medium for carbon steel and medium carbon alloy steel, the heat treatment process commonly used is quenching and tempering process or quenching + high-temperature tempering, and sometimes spheroidizing annealing is also required.

Q18. What is 3D Printing in Mold Manufacturing?

3D printing, a type of rapid prototyping technology, is a technology that builds objects based on digital model files and uses bondable materials such as powdered metal or plastic to print layer by layer. Currently, it is widely used in mold manufacturing, industrial design, and other fields. And it is involved in aerospace, engineering construction, geographic information system, and the medical industry. 3D printing has been given the background of the third industrial revolution and has now entered an era of rapid development, providing a broader platform for improving China’s manufacturing capabilities.

3D printing for Mold Manufacturing

3D printing for Mold Manufacturing

Q19. What are the advantages of 3D Printing of Mold Manufacturing applications?

One very promising application of 3D printing is the direct production of molds. Compared to the traditional mold manufacturing process, 3D printing molds have the following advantages:
1.Save mold production cycle
3D printing can automatically, quickly, directly, and accurately convert the 3D design in the computer into a physical model, and even directly manufacture parts or molds, thereby effectively shortening the product development cycle. It can take shape in a few hours, allowing designers and developers to achieve a leap from the floor plan to the physical one.

2.Save manufacturing costs
Metal 3D printed molds have economic advantages in the production of some small, discontinuous series of end products, or more economic advantages for certain geometric shapes. Especially when the materials used are very expensive and the scrap rate of traditional mold manufacturing materials is high, 3D printing has a cost advantage.

3.Improve precision manufacturing capabilities
Generally, the special metallurgical methods of metal 3D printing can improve the metal microstructure and produce completely dense printed parts, which have the same or better mechanical and physical properties than those forged or cast materials. Additive manufacturing brings unlimited options for engineers to improve mold design. When the target part is composed of several sub-parts, 3D printing has the ability to integrate design and reduce the number of parts. This simplifies the product assembly process and reduces tolerances. In addition, it can integrate complex product functions, making high-functional end products faster, and with fewer product defects.

4.Provide more possibilities for the product
3D printing does not require traditional tools, fixtures, machine tools, or any molds, and can directly generate physical products from 3D CAD graphics of any shape from the computer. Moreover, as the types of materials are increasing, the functions have also changed from traditional homogeneous materials to heterogeneous materials.

Q20. What is Reverse Engineering in Mold Manufacturing?

With the development of computer technology, CAD technology has become an important tool for product designers to conduct research and development. Among them, three-dimensional modeling technology has been widely used in product and mold design, program review, automated manufacturing, as well as management and maintenance. In the actual development and manufacturing process, the technical data received by designers may be three-dimensional models of various data types, but in many cases, they are physical models of products obtained from upstream manufacturers. Designers need to use a certain way to convert this physical information into CAD models, which is applied to reverse engineering technology.