Mold making is the way to production of plastic products of any design and level of complexity. KLONA provides a service for the production of molds – from 3D modeling before starting production in Ukraine, Russia or China. Ordering the production of plastic injection molds is easier than you think.
Press form
The price of a plastic injection mold depends on its performance. In KOLORO you can buy plastic injection molds from 60,000 hryvnia. A more accurate price will be calculated by the manager of the KLONA company after clarifying all the nuances. Contact us for a free consultation.
Mold: price depends on
- type of mold;
- mold making materials;
- circulation of the product;
- overall dimensions of the product;
- the complexity of the geometry of the product;
- requirements for the final type of product;
- terms of project implementation.
KLONA provides guarantee for molds for the entire period of cooperation. We replace any worn part with a new one. To buy a mold with a guarantee, contact our managers.
HOW TO MAKE A MOLD: PRODUCTION STAGES
Equipment for plastic injection molding – a system of complex elements, each of which must ideally match each other. Therefore, the manufacture of molds for plastic injection begins with a critical stage – design.
Mold design
To start a 3D model of the finished product is created , and on its basis the mold is designed. It is believed that the most important part of the design is 3D modeling of technological parts of the mold. Of course, the shape of the parts (matrix and punch) must match – mistakes cannot be made here, because the appearance and quality of the final product depends on this. However, this task is not at all as difficult as designing a gating system, a system of ejection, cooling, etc. The entire production depends on the efficiency of their work – from quality to the final cost of the product. Properly designed and optimized parts can significantly save money and increase productivity.
Analysis and selection of optimal parameters
We carry out a detailed analysis of the mold: modern software products allow our modelers even at the design stage optimize the mold, by choosing a suitable gating system, cooling channels, etc.
Analysis packages allow you to calculate and optimize casting cycle times.
Manufacturing of molds (Ukraine)
All parts of the plastic injection mold are milled on high precision CNC machined hardened steel … Individual parts are coated with a wear-resistant layer. After that, they are assembled and ideally rubbed against each other.
Thanks to the fact that the KLONA company has moved from Kharkov, molds have become even closer to you! Now we are located in the center of Kiev at st. Tryokhsvyatitelskaya 5 / 1А. In our office, you can get the most complete advice on the cost of molds, their technological characteristics and on the spot choose the most suitable mold for your production, which you can buy immediately after filling out the technical task.
Mold testing and test casting
The mold is launched on the injection molding machine. About a hundred closings are carried out to identify defects or inaccuracies. The mold casts the first piece. If any flaws are found, the mold refined until it is perfect.
Depending on the scale of production, there are five types of molds, which are shown below. In the manufacture of all molds are used high quality materials and anti-corrosion steel, and the guide columns are covered with a special wear-resistant layer.
TYPES OF PRESS FORMS DEPENDING ON THE CIRCULATION
Molds with a resource of 1,000,000 cycles
These molds are designed for the highest production run and are characterized by increased durability … The upper limit of the number of products is practically unlimited, since the parts of the mold can be replaced as they wear out. Also, the duration of their use can be increased by making products from non-abrasive plastics. These are the most expensive molds …
Molds with a resource from 500,000 to 999,999 cycles
These molds are designed for high tolerance parts and have medium and high productivity. The creation of a mold of this type takes into account the fact that the molds will be in contact with the abrasive plastic – the forming parts are hardened to a hardness of more than 49HRC.
Molds with a resource from 100,000 to 499,999 cycles
They do a great job. medium and small production. The cost of a mold for medium-sized casting is reduced due to the fact that there are fewer requirements for technical equipment. For example, cooling channels do not have such a complex design as a high-performance mold.
Molds with a service life of up to 99,999 cycles
For release limited batch of products use molds with little resource.
WHY MAKE MOLDS: APPLICATIONS
Molds are used to obtain any plastic products – from ballpoint pen cap to rocket parts. With their help, components and cases for household appliances, office supplies, children’s toys, medical devices, automotive and engineering industries, construction needs, etc. are manufactured. Molds are used to make all kinds of containers and packaging materials.
TYPES OF MOLDS DEPENDING ON THE METHOD OF MANUFACTURING PLASTIC PARTS
Direct compression molds
In such molds, the material is loaded into a die, after which it is heated, becomes plastic and compacted under the action of a punch. When the product is finished, the mold is closed. Depending on the design of the mold, this type of mold is divided into three types.
1. Open
The creation of a mold of this kind does not imply the installation of a loading chamber. … Such molds are used for production of plastic products with a large area (for example, trays). Their disadvantage is the increased percentage of rejects due to underpressure in some cases.
2. Reciprocating
In them, the shaping nest directly continues the loading plane. Their operation requires an exact match between the mass of the loaded material and the resulting product. In such molds it is possible to produce plastic products made of difficult-to-press plastics … Their main disadvantage is the rapid wear of the punch and die.
3.With overflow
Molds of this type are the most common. Their design provides minimum clearance between punch and loading chamber … In this case, a release belt is formed, which ensures complete locking of the design nest.
Depending on the loading chamber, there are:
• with general (for the production of small products of simple design);
• with individual (have a high accuracy of the shaping nest).
Depending on the location of the loading chamber, molds are divided into two types:
• with an upper loading chamber (its use is more preferable when using cassette packages);
• with a lower loading chamber (used on presses with increased force of the lower hydraulic cylinder).
Plastic injection molds
In this type of mold, the loading chamber is connected to the mold nest by means of a gating system. Plastic injection molding is the most popular form of mass production. The injection molds do not have a loading chamber, but the gating system remains. Such molds have a high degree of process automation and allow you to get finished products that do not require additional processing.
1. Stationary
They do not have removable elements, so the mold is fixed on an injection molding machine for the entire period of manufacturing a batch of the product.
2. Semi-stationary
For such molds, removable elements are made that can be alternately installed in the mold, which allows you to speed up the casting process.
3. Removable
These molds are not fixed to the plates and each time they must be removed from the injection molding machine to remove the product. This allows significant cost savings in the manufacture of the mold due to the absence of a system for ejecting parts. However, such molds have low productivity, so they are used in one-off production.
To order the manufacture of injection molds for plastic injection, Contact us.
We will help you choose the best type of mold for your production.
Molds can be single or multiple. It depends on the size of the manufactured products and the circulation. For example, for the production of thousands of small bodies, removable single molds can be used, and for the millionth batch of caps, stationary multi-cavity molds can be used. However, it all depends on the specific case.
CONSTRUCTION FEATURES OF CREATION OF PRESS FORMS
The mold consists of two types of parts – technological and constructive. Let’s take a closer look at these two groups of parts.
Technological parts of molds
These parts are directly involved in the formation of products and come into contact with plastic. These include the following details.
Matrix
Participates in the formation of the outer surface of the plastic product. Most often, matrices are made not integral, but composite, especially for the production of large-sized products. In the manufacture of the matrix, it is necessary to completely exclude the possibility of accidental ingress of material into the gap between the matrix and the loading chamber.
Punch
Press punches form the inner surface of the product. Like matrices, they are usually prefabricated.
Clips
These are the details that connect the design elements. They are characterized by a simple design. Although they are not directly involved in the formation of products, they are under heavy stress and wear out quickly.
Earbuds
Small parts that fit into a die and / or punch to create depressions or holes in a product. Inserts significantly save time and money in the production of the matrix, because machining on machines can be too complex.
Thread
To obtain an internal thread, threaded marks are installed, and for an external thread, threaded rings.
Structural parts of molds
This group unites parts that do not take part in the formation of the product. However, they are very important, because they ensure the work of parts from the first group. For example, column guides, pushers, etc.
Gating system
The gating system is a channel system that transfers the molding material from the nozzle of the injection molding machine to the mold cavity. Gating systems are hot and cold. Hot runner systems are capable of providing “runnerless” casting – when using them, a sprue is not formed, which is a part of the casting and goes to waste.
How to order a mold (Ukraine)
In order to buy a mold, you just need to contact us in any way convenient for you. We will provide you detailed information about our production, as well as help you choose the best mold for you.
