MOULD MAKING

&
DESIGN
Present Approach Of Mold Design

Minimum of 3 months
Production
Trials
Corrections
Activity

Trials
Mold Manufacturing
Order Material
Mold Design
Product Design
Lead Time
➤ To reduce
❖The no of trials.
❖The time to prove the Molds.
❖The launch time of the new product.
❖ Development Time.
❖ Rejection Rate.
❖ Production cost per Piece.
➤To achieve optimum Wall Thickness.
➤To optimise
❖Product Design.
❖Cycle time.
❖Shot weight.
❖ Mold Design.
❖ Processing Parameters.
➤To Increase
❖Profit.
❖ Quality
❖Energy saving.
➤The bottom line:
• Cost savings
• Time savings… reduce time to market!
• Create more reliable, better-quality designs
 CAD/CAM Based Approach

Concept design

3-D modelling CAE analysis

OPTIMISATION

Manufacture
 Resin Part Designer
Supplier

Part design &

Resin supply & Material
Compounding Compounding
CAE &
Shared
Process Design
Information
Molder Optimization Mold
Design
Mold
Mold Designer
Manufacturing

Mold
Maker
Processing Time Analysis

Injection Time 5 to 10 %

Holding /Packing Time 10 to 15 %

Cooling Time 70 %

Mould Open / Close Time 10 %

Cooling Time Constitutes 25 % of

Total Production cost
 Product, Product drawing &
Production specification
 Production Volume (requirement in time)
 Estimated Moulding Cycle (Cycle time)
 Is the Drawing clear ?
 Projection
 1st angle, 3rd angle
 Tolerances
 Notes on Drawing – Draft angle, etc.
 End use requirement
 Moulding Material
 Shrinkage
 Factors to be considered during the
Design
1. Optimum production requirements/time
2. Number of Cavities and Layout of Cavities
3. Selection of Moulding Machine
4. Layout of Cavities
5. Type of Mould
6. Design of Feed system
7. Temperature control (Cooling system)
8. Design of Ejection
9. Design of Runner and Over flows
10. Shrinkage consider by volume of Component
11. Mould Material
 Number of Cavities in a Mould

Factors that controls the Number of Cavities

in a Mould are:
a. On the Machine Side:
Shot capacity
Solidifying capacity
Clamping force
Pressure
Size of the Platens

b. On the Component Side:

Projected area of the Moulding (Clamping force)
Configuration of the Moulding (Pressure)
Wall thickness of the Moulding (Pressure)
Size of the Moulding (Mould size, Platen size & Flow length)
C On the Material Side
• Pressure
• Material Temperature
• Mould Temperature
• Density of the Material Shot Capacity
• Bulk Factor of the Material

• (Crystalline and Amorphous Materials) Solidifying

• Total thermal heat content of the Material at the
Capacity
Moulding Temperature
 INJECTION PRESSURE

Injection pressure inside the mould

will depends on:
The flow characteristics of the
material
Thickness of the moulding
Cavity depth
Projected area of the moulding
Flow length
Type, size and finishing of the feed
system.
 Layout of Cavities:
For efficient and Economical Layout the following points to be
considered during Layout of the Cavities.
Optimum disposition of Cavities
Minimum Runner length
Balanced Layout
Optimum disposition of Cavities
 Reduce the Mould size
 Reduce the Mould cost.
Minimum Runner length
 Reduce the pressure drop
 Fill all the cavities with required pressure and
temperature.
Balanced Layout
 Attain uniform clamping
 Prevent local flashing of the mould.
 6. Design of Feed system

Feed system connects

The flow of the material from Spreader to the cavity

Feed system contains

Sprue alone (Direct sprue gate) or
Sprue, runner and gate in multi-impression moulds
(a) Runner Design
The designer should keep in mind the following points during
design of runner.
Shape and Cross section of the runner
Size of the runner
Layout of the runner
Shape and Cross section:
Various shapes and cross sections are:
Circular
Semi- circular
Trapezoidal
Hexagonal
Square
Rectangular