Step 1>. Part DFM & Refine
When we take a project from our client, the first thing we do is to perform a DFM, which helps client to check out part thickness, strength, fitting, and injection molding ability. Meanwhile, we will provide improvement solution or revise part design directly, and send stp file to clients for confirmation.
Step 2>. Mold Design
Once the part refine process is finalized, our professional mold designers would start with mold design job, at this time, a mold design DFM report will be sent to clients for review prior to 3D mold design, which includes mold steel, mold layout, injection gate position & type, parting line, sliders & lifter deployment, ejection pins, and cooling channel. In this way, our client can clearly understand how the mold design will go forward.
If our client confirmed our mold design DFM, then we will begin 3D mold design immediately.
Step 3>. Mold Base, Mold Steel, & Standard Parts Sourcing
As soon as our mold design drawing is confirmed by client, we will out-source mold base, mold steel, injection pins, sleeves, or hot runner if have.
Step 4>. CNC Machining
CNC machining is the first mold manufacturing process, which is used to make some mold cavity, mold core, sliders, or lifter. If any EDM process needed, we will keep a 0.2mm remaining material based on design drawing.
Step 5>. Wire Cutting
Wire cutting is a quick way to manufacture some sliders, lifters, or insert components. Meanwhile wire cutting can be used to obtain holes, slots, and other shapes of mold features.
Step 6>. EDM
EDM is known as electric discharge machining process that used to make mold features with accurate dimension. During the process, a discharge copper is mounted on EDM machine, it gives spark discharge or sink discharge to remove material from work piece.(mold steel).
Step 7>. Polish
In order to obtain a certain finish of part. We need to polish the mold cavity or mold core. For different level of finish, we can categorize them as mirror polish, high polish, or normal polish. On the other hand, a polish can help part to be ejected from mold tool easier without scratch while injection molding production.
Step 8>. Mold Fitting and Assembly
Prior to mold assembly, we will get all of mold components inspected by CMM machine, and ensure each mold parts are accurately manufactured based on our mold design drawing. After that, our mold makers will get them assembled and fitted.
Step 9>. Mold Trial
Mold trial is a useful process to check out if our mold tool is correctly designed or manufactured. Our mold QC will check out the first molded sample. If everything is OK, we will send 10 pcs of sample to clients for review. If not, we will take quick troubleshooting action, so that the first molded sample can be produced and shipped to clients for review.
Step 10>. Mold Refine
40% of our mold has a perfect performance when first mold trial, however, 60% of new mold exists some imperfection or defects. So we need to improve our mold tool immediately after first mold trial. And try to fix all of problem as sooner as possible.
Step 11>. Texture
If mold tool is completely refined, the last step we do is to add some texture on mold tool. So that our molded parts will have a good touch feeling or appearance. We perform VDI 3400, Mold-tech, Yick Sang…as our standard texture sample. If any special texture needed, our client will have to send us physical samples for reference.