Plastic Injection Molding Service Case Study

Plastic Injection Molded Project Case Study

Product Description: Fence Clip

Primary Capabilities Applied: CNC plastic prototypes, Mold Design, Mold Manufacturing, Injection Molding

Cavity Number: 1X2

Tool Steel: H13

Moulding materials: Zytel 101L

Molding Equipment: Engel 110T

Masterial Finish: EDM Surface

Delivery Location: Australia

Part Design Optimization

Over the years, Stebro Mold has created and continued to improve plastic injection molded components for various customers. The goal is to make the product the best of the best. The injection molded component is designed with a molding strategy that keeps costs low and working properly.

Design for manufacturability Report

Of all the design requirements, meetings, specifications and documentation involved when it comes to injection molded plastic parts, one of the most critical elements of the design process is often overlooked: a formal Design for Manufacturing (DFM) analysis. It is a bridge between product developer and mold manufacturer.
 
Below is a partial list of items typically covered by a DFM analysis:
  • Product information such as part material, size, weight, tolerance and surface.
  • Product feature checking such as draft angel, wall thickness and ribs.
  • Analysis such as Weld Lines, sink mark and Warp.
  • Mold information such as cavity numbers, steel, mold layout, parting line, runner system, gate type, ejection and cooling system.

CNC Plastic Prototype

CNC Plastic Prototype Manufacturing

The plastic material is PA66GF30.

CNC Plastic Prototype Parts

With the CNC plastic prototype parts, customer can test the 

Injection Mold Designing

Mold Tool Design

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Cooling Channels

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Mold Flow Analysis

Taking the mold from good to great is as simple as testing it via Mold Flow Analysis. We do the Moldflow before the injection mold manufacturing to see the warpage.

There are multiple benefits to MFA as below:

  • Resolution of wall thickness complications
  • Gate location optimization
  • Mold cavities fill consistently and uniformly
  • Discover defects in design geometry
  • Prevent expensive tooling errors and rework
  • Enhance manufacturability
  • Reduce time to market
  • Boost efficiency and quality
  • Reveals potential visual defects, including air traps, sink marks and weld lines
  • Assess different material options, pre-production
  • Provides data to support design changes

Injection Mold Manufacturing

CNC Manufacturing

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EDM Manufacturing

The size for this part is small. It can save the cost and short the lead time if we do all the surface by EDM as we do not need to do the polish and texture on the mold.

Mold Fitting

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Injection Molding

Injection molding Test

Customer did not specify the trade name of the plastic material. We run the mold test in PA66, PA66GF10, PA66GF15 and PA66GF30, then customer can test the function with different material and choose the best one.

Injection Molding Production

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Customer Feedback

Keys to Winning the Business: As a full service custom plastic injection molding supplier from design to delivery, providing an affordable tooling and part price for the customer was the key to this project’s success. Our collaboration includes part design optimization, material selection, mold design, mold manufacturing, injection molding production to reduce cost and increase efficiency without sacrificing quality.

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