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Mould Design 3

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Mould Design 3 ---Aheadmold

To ease maintenance and venting, cavities and cores are divided into pieces, called inserts, and sub-assemblies, also called inserts, blocks, or chase blocks. By substituting interchangeable inserts, one mould may make several variations of the same part.

More complex parts are formed using more complex moulds. These may have sections called slides, that move into a cavity perpendicular to the draw direction, to form overhanging part features. When the mould is opened, the slides are pulled away from the plastic part by using stationary “angle pins” on the stationary mould half. These pins enter a slot in the slides and cause the slides to move backward when the moving half of the mould opens. The part is then ejected and the mould closes. The closing action of the mould causes the slides to move forward along the angle pins.

Some moulds allow previously moulded parts to be reinserted to allow a new plastic layer to form around the first part. This is often referred to as overmoulding. This system can allow for production of one-piece tires and wheels.

Two-shot injection moulded keycaps from a computer keyboard

Two-shot or multi-shot moulds are designed to "overmould" within a single moulding cycle and must be processed on specialized injection moulding machines with two or more injection units. This process is actually an injection moulding process performed twice and therefore has a much smaller margin of error. In the first step, the base color material is moulded into a basic shape, which contains spaces for the second shot. Then the second material, a different color, is injection-moulded into those spaces. Pushbuttons and keys, for instance, made by this process have markings that cannot wear off, and remain legible with heavy use.

A mould can produce several copies of the same parts in a single "shot". The number of "impressions" in the mould of that part is often incorrectly referred to as cavitation. A tool with one impression will often be called a single impression (cavity) mould.[16]:398 A mould with 2 or more cavities of the same parts will likely be referred to as multiple impression (cavity) mould.[16]:262 Some extremely high production volume moulds (like those for bottle caps) can have over 128 cavities.

In some cases multiple cavity tooling will mould a series of different parts in the same tool. Some toolmakers call these moulds family moulds as all the parts are related. Examples include plastic model kits.

Mould storage

Manufacturers go to great lengths to protect custom moulds due to their high average costs. The perfect temperature and humidity level is maintained to ensure the longest possible lifespan for each custom mould. Custom moulds, such as those used for rubber injection moulding, are stored in temperature and humidity controlled environments to prevent warping.

Tool materials

Tool steel or beryllium-copper are often used. Mild steel, aluminum, nickel or epoxy are suitable only for prototype or very short production runs.[1] Modern hard aluminum (7075 and 2024 alloys) with proper mould design, can easily make moulds capable of 100,000 or more part life with proper mould maintenance.Beryllium-copper insert (yellow) on injection moulding mould for ABS resin.

Article come from AHEADMOLD,website is WWW.AHEADMOLD.COM.

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