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Follow basic rules when making a production-capable prototype tool. If you are contemplating construction of an eightcavity tool, you can build a single cavity for the prototype process, validate the process, and then make the other seven core and cavity sets, says Warkoski. Its the most expensive prototyping option, but production of an actual core and cavity set in production materials is the only way to make sure the prototype part has the same mechanical properties as the production part. One caution: if you go the single core and cavity route, make sure fill time is unchanged when you go to a multi-cavity tool. If a single cavity operating alone fills in two seconds, then the screw injection velocity on the injection molding machine would need to be four times higher to ensure similar fill rates in a four cavity tool. There are other important nuances to consider as well. Its a common practice to use hand-loaded inserts to avoid use of expensive side action in prototype tools.
Size Limitations
One of the constraints may be size. One service bureau, Protomold of Minneapolis, lists these size requirements:
Maximum part outline is approximately 7.5 inches by 14 inches. There is, however, an overall limitation of 75 square inches of projected mold area. Maximum part volume is about 15.75 cubic inches. Maximum part depth is 3 inches if the parting line can pass through the middle of the part or 1.5 inches if the parting line must be at one edge.
Protomold can support simple undercuts-up to four side actions per mold, and they all must be at the parting line. Side pulls must be perpendicular to the primary (A-B sides) pull direction. There are also some limitations created by the CNC machining process, such as inability to make sharp corners. These types of prototype tools are made from aluminum and can be used
for limited production quantities in some cases. Potential runs depend greatly on materials and processing conditions. Highly glass-filled compounds run at high pressures can reduce tool life to less than 40 parts. Unfilled resins run at low pressures permit tool life beyond several thousand parts. Tools like this made by service bureaus are generally based on two-plate mold designs. Straight pulls are used for ejection. Steel or aluminum? Go back to your initial analysis of the relative importance of speed, quality or cost (see triangle diagram).
Construction of single-cavity core and cavity sets from production metals produces parts with the best functional characteristics. Placement of choices here is highly relative and can vary widely based on part and process specifics.