Injection Molding – DDPROTOTYPE

Rapid Tooling Case

Martin.mu — Wed, 12 Jun 2024 01:01:24 +0000

Project Overview:

Manufacturing Process: Rapid Tooling | Plastic Injection Molding
Tooling Material: NAK 80
Molding Material: Fire Retardant PC+ABS
Tooling Life: 300 Thousands Shots
Quantity: 2000 Units
Lead Time: 20Days

Customer was an America based company specializing in developing products in medical devices. Considering production volume, consistent quality, cost & time saving, rapid tooling and injection molding was the ideal process. In addition, we offered two suggestions to improve the product’s fitting also reduce its manufacturing cost.

DDPROTOTYPE provides aluminum mold and steel mold for rapid tooling according to the needs of customers. It can hand over the parts of your designated materials within 2-5 weeks. we combine rapid injection molding advanced equipment with proprietary technology and experienced manufacturing teams to help you reduce design risk and save overall production cost.

Electrical Discharge Machining (EDM) the back tooling core. To reduce the cost and time of tooling fabrication as well as the injection molding, the two parts were put into one tooling with one cavity of each part.

The CNC and EDM milled front tooling core prior to sanding and texturing. EDM was usually to mill the CNC round corners to straight or sharp ones, also mill the complex features that were out of CNC capability.

Placing M2 brass nut for insert molding. Since customer was new to injection molding technique, we offered the design optimizations to place M2 nut well and improve the parts fitting, also reduce tooling cost.

The injection molded parts for delivery. We not only make prototypes and parts, also help customers in right direction to save money and time, we do believe the customer’s success is also our success.

The post Rapid Tooling Case appeared first on DDPROTOTYPE.

Rapid Tooling

Martin.mu — Tue, 11 Jun 2024 01:04:36 +0000

DDPROTOTYPE provides aluminum mold and steel mold for rapid tooling according to the needs of customers. It can hand over the parts of your designated materials within 2-5 weeks. From functional prototyping to low volume production to mass production of parts, we combine rapid injection molding advanced equipment with proprietary technology and experienced manufacturing teams to provide high quality injection molding parts, so as to help you reduce design risk and save overall production cost.

Rapid injection molding service

Low volume production is the best way to save time and cost to test the shape and assembly of products and to conduct preliminary market test, but in any case, it can not meet the final surface treatment and functional effect of injection molding plastic parts. If your production mold is extremely complex and takes months or even longer to be ready, then rapid tooling (also known as fast tooling) is the ideal choice for you to quickly mass produce parts at a lower cost.

Our capabilities

DDPROTOTYPE invested in an independent injection molding plant in 2016 to provide rapid injection molding and traditional injection molding services using a variety of materials and technologies, as well as bridge tools for prototype testing and pre mass production evaluation. We will deliver injection molded parts according to your plan and help solve any problems that may arise in the whole production process.

At DDPROTOTYPE, we have a team that specializes in rapid tooling for aluminum and steel. With technical experience in injection molding, rapid injection molding, CNC machining, EDM / WEDM machining and special finishing, ensure that the parts produced meet and exceed your highest expectations.

Rapid Tooling Service

Our proprietary rapid injection molding process and experienced team focus on your project, enabling us to shorten the time to manufacture the mold and thus faster delivery time. Don’t worry about your design beyond our tolerance, because no matter what industry you are in and how complex parts you need, we have the corresponding equipment, ability and knowledge to deliver your special material parts within 2-5 weeks. It’s that simple.

Rapid injection solution for small batch production

Rapid injection molding can not only conduct hundreds of trial production for the test prototype close to the final product, but also produce the final use parts on demand for small batch production. No matter how many parts you need, ddprototype gives you better advice on mold life and process technology.

At DDPROTOTYPE, we combine traditional injection molding methods with rapid mold processing to produce plastic parts with high quality and high efficiency. DDPROTOTYPE takes an active approach to plastic projects, providing cost-effective and reasonable suggestions from design, materials, production process, manufacturability, etc. We will determine the best way for you to enter the market according to your project objectives and expectations. From the beginning, our engineers and molding masters can reduce the pain and time of this process to ensure that your parts can be molded as expected.

DFM optimization

DFM covers all aspects of the injection molding process, from part design, mold design, material selection to processing. With 15 years of practical experience in traditional mold manufacturing and rapid mold manufacturing, our engineers will conduct comprehensive interactive quotation and manufacturability analysis, and be able to conduct design review to recommend the best technology for your parts. Including gate type and location, parting line, draft, runner system, sliding and insertion, ejection, key dimensions, tolerances and surface finish, all of which are very important in production. Design problems can be found without waiting for production, because by optimizing the design for manufacturability, our engineers will ensure that your parts can be mold processed and shaped to save as much cost as possible.

Choose the right mold material

At DDPROTOTYPE, we can provide complete mold manufacturing capability and instant support for tool modification. From prototyping to production tooling, we can use 7075 aluminum, P20 and NAK80 aluminum semi hardened steel and H13 all hardened steel to make injection tools. Choosing the right mold material for your project is critical to making parts. In general, this will involve considerations such as intended use, volume requirements and expected investment as well as design complexity, mold structure, etc. If you are not sure which one to choose? We will help you weigh each of these advantages to find the best solution to meet your needs.

In addition, we offer standard SPI coating, EDM texture and a series of etched textures, including mold tech ® MT series and VDI ® 3400 series.

AL7075 Die

DDPROTOTYPE has many years of experience in creating fast aluminum molds. Generally, the aluminum die (aircraft grade aluminum) made of al7075 is as strong and durable as the traditional P20 die. Due to its light weight and good machinability, compared with hard steel, aluminum mold reduces the cost of manufacturing mold, because the processing speed of aluminum is 15% – 30% faster, and the polishing speed is 3-10 times faster. Due to various factors, including cost, delivery time, quantity and so on, many injection molding companies begin to pay more attention to aluminum injection mold and tools.

Are there complex part designs, tight tolerances, and various surface finishes and textures? Don’t worry that our aluminum mold processing technology can deal with it. We won’t ask you to make any changes and allow you to enter the market at the fastest possible cost.

low-volume manufacturer

DDPROTOTYPE is a low-volume manufacturer that can provide a wide range of injection molded parts, ranging from 100 to 100000. Every time, we use unparalleled expertise to provide quality and repeatability for every part. Ddprototype is a reliable manufacturer of plastic parts that can do all the work under one roof, including design and mold manufacturing, tool debugging, material selection and injection molding process. This means that your business is easy to manage and doesn’t waste time or money dealing with inefficient processes. In this way, it can be understood that ddprototype operates the automatic assembly line.

When the design is perfect and the number of parts you need increases greatly, DDPROTOTYPE will help you turn to traditional mold production. As an experienced injection molding partner, we simplify manufacturing through a variety of cost-effective options to meet your needs. Multiple solutions for customized plastics mean you can use a single source to handle everything from production to delivery.

Latest Blog Post

How Prototype Machining

Watch Our Latest Video

The post Rapid Tooling appeared first on DDPROTOTYPE.

Plastic Injection Molding

Martin.mu — Fri, 31 May 2024 17:37:23 +0000

DDPROTOTYPE combines the latest injection moulding technology and expertise to provide rapid tooling and plastic injection moulding services at competitive prices. We have experienced injection moulding project team to support us in providing high-quality injection moulding parts. Plastic Injection moulding services include high-quality aluminum prototype moulds for low-volume production and full-scale production of hardened steel moulds. Provide feasibility analysis of die design and manufacturing, from simple parts to complex parts, and have the ability to produce 50-100,000 finished parts. We can offer a variety of plastic resins, customized color and surface treatment options. The production of parts can be completed within 15 days by using rapid tooling.

Our Capability

Our rapid tooling and injection moulding services involve CAD/CAM parts and die design, manufacturability design (DFM) and Moldflow simulation. We offer options for cladding, insert and screw-down moulding, as well as weekly progress reports and die tracking reports.Through advanced material validation and quality process, we can ensure that your die and parts meet your target requirements, or even exceed your expectations. If you are ready to start the next project, please upload your product design information immediately to obtain a competitive injection molding quotation.

What is the role of rapid manufacturing?

You don’t have to wait weeks and months and commit to high capital expenditures, and the aluminum tools they get usually start at a few thousand dollars and can produce more than 10000 parts, or even tens of thousands of parts. The result is not only short-term parts within a few days, but also high-quality plastic and metal parts.The automation design for manufacturability (DFM) analysis is another important advantage of software automation for rapid manufacturing customers.

They can upload CAD models online and get design feedback within 24 hours to determine exactly what adjustments need to be made in the CAD model to improve its manufacturability. In turn, this reduces production problems and ultimately saves production costs.If equipped with rapid manufacturers, the company can shorten the product development cycle, reduce technology and supply chain risks, and reduce the total cost of development and inventory.

Wide Material Selection

We stock more than 100 different thermoplastic resins and accept customer-supplied materials. Our selection of injection molding materials includes:

PA (nylon)
PMMA (acrylic)
Polycarbonate (PC)
ABS
HDPE
POM (Acetal/Delrin)
PEEK
TPU
TPE/TPV

Our Advantages

1 High efficiency

It can be produced 24 hours and a large number of plastic parts can be produced in a short time. Our team will guide you through all steps of the injection molding process. Free DFM feedback.

2 High-strength components

The strength of the moulded parts can be enhanced by adding special fillers to the liquid resin. Strictly according to customer’s customized color production.

3 Low Cost

The repeatability of injection moulding usually results in low cost of each component. In addition, it provides low-cost aluminum rapid tooling options.

4 Ready-to-use:

As long as the mold is properly finished, the injection parts will be removed from the mold, and the appearance is smooth without further processing.

5 Detailed features

With the technical reserve of multi-cavity, complex mould and secondary injection moulding, high-pressure injection moulding is adopted, and injection resin can reach every sharp corner, allowing large-scale production of complex structural parts. Machine pressures range from 50 to 2,000 tons, providing all industry standard materials.

6 Strict Tolerances

Professional DDPROTOTYPE employees work tirelessly behind the scenes to ensure that your parts are manufactured on time and meet your precise specifications. We have passed ISO 9001 and ISO 13485 quality certification.

Plastic Injection Molding Video | DDPROTOTYPE

What materials do you use to make tools?

It depends entirely on the number of parts needed. The higher the expected number, the more difficult the tool material is to resist the wear of multiple moulding cycles. Although each case is unique, please refer to the following table as our starting point for your specific components:

Low-Volume

Tool Life: 1,000-10,000 parts

Tool Material: Aluminum or S50C steel

Tool Lead Time: 1-3 weeks for general tooling (may be slightly longer for more complex tools)

Medium-Volume

Tool Life: 10,000-100,000 parts

Tool Material: P20 steel or 738H steel

Tool Lead Time: 2-4 weeks for general tooling (may be slightly longer for more complex tools)

High-Volume

Tool Life: 100,000-1,000,000 parts

Tool Material: NAK80 or S136 steel

Tool Lead Time: 4-6 weeks for general tooling (may be slightly longer for more complex tools)

If I need really high quantities of parts, what steps do you take to assure my parts are as inexpensive as possible?

We look at many different ways to assure the lowest cost parts possible.

We use well-engineered cooling systems to reduce the cycle time.
Where applicable, we use multi-cavity tools to meet large volume capacity and reduce part cost.
We often use hot tip gates, sub gates, hook gates, and automatic cutting gates to reduce labor cost.
We have mechanical arms and conveyor belts installed on our Injection Molding Machines to help handle the molded parts automatically and efficiently.

It will take 20 minutes to read guide to reduce cost.

What is Rapid Molding and Injection Molding?

Rapid tooling is a form of rapid prototyping manufacturing, which involves the process of creating mould rather than part, and creating mould using rapid prototyping technology to create multiple copies of parts.

Aluminum or mild steel is generally used as the material for rapid tooling. This is one of the appropriate ways when traditional tools are either expensive or not necessary for the required parts or volumes. Therefore, this is a perfect way to minimize costs when market testing requires small batches and will not require large batches in the future.

Injection Machine List
No.	Origin	Brand	Code	Amount	Clamping Force	Tie Bar Distance (mm）	Mold Thickness （mm)	Mold Open Stroke (mm)
1	Japan	TOYO	TOYO SI180	1	180T	560*560	250-600	470
2	Japan	TOYO	TOYO SI230	4	230T	610*610	250-680	550
3	Taiwan	HWA CHIN	HC80	2	80T	320*320	140-350	350
4	Taiwan	HWA CHIN	HC160	17	160T	460*450	150-500	500
5	Taiwan	HWA CHIN	HC210	7	210T	500*500	270-550	550
6	HongKong	L.K.	PT160	4	160T	459*459	200-450	400
7	HongKong	L.K.	PT200	6	200T	510*510	200-520	460

Create Dies

DDPROTOTYPE often uses its experience in CNC machining to create dies, but it can also use 3D printing and other to create dies.

Injection moulding is the process of injecting molten resin materials into mould to produce large numbers of parts. Because of its high accuracy, repeatability and large-scale cost-effectiveness, injection moulding is used to manufacture products and components ranging from minimal medical plug-ins to large-scale automotive and aviation parts.

In the process of injection moulding, the resin material is heated and mixed, in which the reciprocating screw injects the melted resin material into the separate mould, then injects the material into the cavity under high pressure, cools in the cavity and solidifies into the appropriate shape to form the final plastic parts.

When used in conjunction with rapid tooling, injection moulding is very efficient and can create parts at low cost in a very short time.

The key steps of injection moulding process:

1 Clamping: Close both sides of the die and be sure to clamp.

2 Injection: The resin material is fed into the machine and pushed into the mould. The material melts due to heat and pressure and then injects plastic into the mold – this is called “injection”.

3 Cooling: The plastic in the die is cooled and solidified into the shape of the part.

4 Ejection: After the parts are cooled, they eject from the die.

Advantages of Injection Molding

Because of the high pressure characteristics of injection moulding process, it is much easier to manufacture parts with detailed features or complex geometric shapes, which are too expensive by CNC machining. The characteristics of repeated use of dies over a long period of time lead to extremely high productivity, which is more cost-effective and efficient than other manufacturing processes. Different injection moulding processes, such as cladding and insert moulding, allow you to create plastic parts with unique characteristics, such as enhanced strength, soft grip surface or increased flexibility.

Latest Blog Post

How Prototype Machining

Watch Our Latest Video

The post Plastic Injection Molding appeared first on DDPROTOTYPE.

Design Guidelines For Injection Molded Plastic Parts

Martin.mu — Fri, 31 May 2024 15:04:48 +0000

Design guidelines for injection molded plastic parts

For design engineers who are not familiar with plastic injection molding design, there may be a knowledge gap in ensuring that CAD models are designed correctly for the manufacturing process. Some very specific design features must be considered in the design phase to avoid the problem of moldability, which can produce undesirable results in molded parts. If they are not considered at the beginning of the design process and are not discovered until after the design for manufacturability (DFM) review, design changes may increase the time and cost of injection molding projects.

The draft angle is an example. If the part is not designed with the demoulding angle at the required place, it may not be able to eject cleanly and smoothly from the mold, and the part with appropriate demoulding angle must be redesigned.

To avoid expensive and time-consuming design errors, we have created a design guide for plastic injection molding. It provides information about the most important design requirements so that perfection can be achieved in the initial design phase. The following example prompts illustrate the type of information provided in the complete guide to download the complete design guide.

Bosses find use in many part designs as points for attachment and assembly. The most common variety consists of cylindrical projections with holes designed to receive screws, threaded inserts, or other types of fastening hardware. Generally, the outside diameter of bosses should remain within 2.0 to 2.4 times the outside diameter of the screw or insert

It is suggested avoiding bosses that merge into sidewalls because they can form thick sections that lead to sink. Proper bosses should be positioned away from the sidewall, and if needed, use connecting ribs for support. Try using open boss designs for bosses near a standing wall.

The post Design Guidelines For Injection Molded Plastic Parts appeared first on DDPROTOTYPE.

Lifetime mold warranty of injection mold

Martin.mu — Fri, 31 May 2024 12:09:50 +0000

DDPROTOTYPE provides different types of plastic injection mold, and provides different warranty to meet your production requirements. If you need a prototype or a low volume part mold, we guarantee that the prototype mold can hold up to 10000 pieces. However, if you need a larger number of plastic parts, we will provide lifetime mold warranty on all production molds.

Lifetime injection mold warranty means that we will maintain and renovate the mold as needed during the service life of your mold without any cost to you. As long as we run your parts in the manufacturing plant, your mold has a lifetime warranty under the terms and conditions of DDPROTOTYPE.

Quotations

DDPROTOTYPE will correct design defects that are not conducive to injection molding before mold design. If at any time during the processing of the order there is a plastic defect and it has been identified, the customer will be informed. If the customer agrees, a design change will be made, otherwise the order will be void and the advance payment will be returned in full. When the customer’s design is not conducive to industry standards and / or DDPROTOTYPE molding technology, DDPROTOTYPE will provide design change suggestions. Tools and parts quotations are based on the size and weight of the parts listed in the quotation. The customer is responsible for verifying the parts listed in the quotation that meet the customer’s part design.

Pricing and payment terms

All prices are in US dollars and payment shall be made in US dollars. According to the customer’s credit report, at least 50% down payment is required to start mold production. The remaining tooling cost will be invoiced when the sample parts are shipped. Payment for parts is separate and prepaid. Five samples will be provided to the customer for inspection and acceptance of the mold. The customer shall have a period of 5 working days from the date the parts are received for sample approval. If DDPROTOTYPE is not informed of non-compliance within this time period, the customer confirms approval and pays. Payment terms for parts have been prepaid with the order. Acceptable payment methods include wire transfers, ACh, checks, and credit and debit cards, including MasterCard, visa, American Express and discover.

Tooling

All tools are based on customer supplied 3D CAD data, which replaces any conflict with 2D dimensional or geometric data. The first quality report of five samples of key dimensions indicated by the customer is provided free of charge. Refer to full-scale layouts, CMM reports, or more as needed.Once paid in full, the customer will assume ownership of the mold core. If a replaceable die holder is used, the customer has ownership of the die core. Ddprototype will maintain and store customers’ tools free of charge for three years of idle time. During this period, all tools are only used to manufacture parts for the original customer or his authorized partner. However, the dynamic characteristics of the injection molding process will not guarantee the accuracy of the part. After adding shrinkage, cut the mold to a standard tolerance of + / – 0.005 inches. The standard tolerance for CNC machined parts is + / – 0.005 inch for plastic parts and + / – 0.002 inch for metal parts.

Part design iteration

DDPROTOTYPE will modify the tool to support design changes to the quote. DDPROTOTYPE reserves the right to determine the suitability of the die modification and manufacture of new tooling. For each part run or tool sample resulting from a customer driven mold design change, an installation fee will be charged based on the size of the injection molding machine required. Changing or adding plastic resins or colors will result in additional trial and approved samples for which the customer will be quoted. Each change of color during part operation will incur costs.

Part usage and destination

It is the customer’s responsibility to comply with all applicable laws or the laws of any country and / or territory relating to the direct or indirect use of the parts and their final destination. The customer also certifies that the 3D CAD data submitted to DDPROTOTYPE does not produce products that violate gun law or any other international government law. DDPROTOTYPE is not responsible for any violation of firearms law or any other international government law resulting from the manufacture, delivery or use of any design product provided by the customer.

Warranty

DDPROTOTYPE is not responsible for the design of the products generated by this transaction. All designs are the result of the customer providing ddprototype with 3D CAD design to produce the customer’s goods, whether the products are designed by the customer or approved by the customer for the third party production.

DDPROTOTYPE is responsible or responsible for the materials selected by customers for the production of their parts. Although the project manager of DDPROTOTYPE may suggest which material may be a better choice for the production of customer goods, DDPROTOTYPE and / or its representatives will not express, imply or choose which material to use in the production of customer goods. The selection of the above materials is the sole responsibility of the customer for their goods. Customers shall be responsible for their own due diligence and research to understand that the material and design of their products best comply with government regulations regarding health and safety, CE, FCC, FDA, FMCSA, ISO, NSF, UL and USP requirements, strength, durability and / or flexibility, or other regulations not mentioned or implied at present or in the future. This also includes the special materials purchased by iconold according to the requirements of customers, and the special materials provided by customers to icomold for customers’ goods.

After receiving the export mold, the customer is responsible for ensuring that the mold meets the specifications of the part 3D CAD model provided by the customer. The customer shall have 30 days to notify DDPROTOTYPE of any non conformity. If DDPROTOTYPE is not informed within 30 days after the customer receives the mold, the customer confirms that the mold has been accepted and meets the requirements. DDPROTOTYPE will review any issues of customer’s attention that are not consistent with the 3D CAD model of the part. If DDPROTOTYPE agrees with any non conformity, it may, at its sole discretion, allow the mold to be returned to its mold manufacturer in Shenzhen, China for rework. If the return is approved, DDPROTOTYPE will pay the shipping cost of the mold. If the customer needs air transportation, the customer will pay the difference between the cost of shipping and air transportation. DDPROTOTYPE is not responsible for any business loss, loss of revenue or any loss arising from the return of export molds for rework.

Confidentiality / Privacy

DDPROTOTYPE will do its best to maintain the confidential information of its customers, and we will do our best to maintain the confidentiality of the information submitted, whether it is personal / company information, CAD files, quotations or orders. In addition, our employees understand that documents and information submitted to DDPROTOTYPE should be kept confidential as they may contain proprietary information and / or intellectual property rights. In addition, ddprototype agrees not to share confidential information or uploaded files with any person or corporate entity other than ddprototype and its permitted partners. At the written request of the customer, DDPROTOTYPE will delete or erase all electronic data (CAD files) from its computer system, unless data that cannot be accessed by conventional means is electronically archived and / or backed up. All printed and electronic documents relating to customer’s confidential and / or proprietary information shall also be destroyed at client’s written request, unless such electronic data is not readily available to customer. DDPROTOTYPE will confirm to the customer that all electronic data and paper documents have been destroyed and / or erased.

The post Lifetime mold warranty of injection mold appeared first on DDPROTOTYPE.

Mass Production Injection mold

Martin.mu — Fri, 31 May 2024 10:57:18 +0000

What is mass production injection mold?

Mass production injection mold can withstand a larger number of plastic injection molding cycle. They are made of P20 steel or nk80 stainless steel and usually last more than 100000 times. In addition, we provide lifetime warranty service for production molds. As long as we continue to manufacture your parts in our factory, we will maintain and repair the tools as needed at our expense.

Can I make design changes on the production mold?

Yes, using DDPROTOTYPE can make design changes to the production mold. Our engineer will coordinate with you to change the CAD file and rework the mold accordingly. Before production, you will receive the modified samples for your approval.DDPROTOTYPE provides a dedicated project manager and engineer for your injection molding production.

Reduce production and operation cost

Although 3D printing does not have the upfront cost of a mold like a mold, it will not reduce the unit cost with the increase of production, while injection molding will not. With just a few hundred production units, plastic injection molding can quickly become a more cost-effective option.This chart shows the unit cost of a part manufactured by injection molding and the same part that is 3D printed. The initial cost of injection mold is $5000, and the cost per unit is $0.14. The unit cost of 3D printers is fixed at $20. On 255 units, it’s cheaper to make parts with plastic injection molding.

Faster production time

Most of the time of plastic injection molding is spent on the mold itself. In actual production, a set of parts can be created in seconds. For a 3D printer, it can take any time between 20 minutes (a small simple design, such as a washer or nut) to a few hours (a more complex or larger part) to make a part. This means that the production of a large number of parts does not have a significant impact on the total time of plastic injection molding. On the other hand, adding more parts to an order can take a 3D printer days, weeks, or even months to complete the order.

Higher quality products

The most common 3D printer is the fused deposition modeling (FDM) machine. This means that the printer creates a part by repeatedly heating a drop of plastic and adding it once to the part. Allow each layer to cool completely before adding the next layer. This delamination may introduce new structural weaknesses, as these layers are sometimes easily separated. For plastic injection molding, the production mold is completely filled with molten plastic and then cooled. As the parts are integrated, plastic injection molding will not bring any new structural defects.

Advantages of manufacturing injection mold compared with CNC machining – reducing waste of materials

On average, even with additional connections (runner), injection molding produces less waste material than CNC machining. This is because CNC machining begins with a solid block of material from which parts are cut. In a very small production run, this cost can be negligible. In the case of larger production volumes and the use of more expensive materials, this waste can add considerable costs.

Reduce production time

CNC machining does not need any previous tools. Once completed, CAD files can be sent to production. In low volume manufacturing, CNC machining will be brilliant. Once a certain number of parts are obtained in operation (depending on the size and complexity of the parts), parts can be produced faster by injection molding.The biggest time waste of plastic injection molding is the creation of production mold. Once the production mold is created and set up correctly, parts can be produced in just a few seconds. In the production process, the more parts, the more time saving compared with CNC machining.

Higher production cost, lower cost

For CNC machines, each part must be manually put into or taken out of the machine, so the cost of each part in the production process is quite fixed. For plastic injection molding, the production mold is by far the most expensive product. After the mold is created, the parts are quite cheap and the production speed is fast. Because of the rapid speed of plastic injection molding, and once the production mold is established, there is no need for manual intervention, so the cost per piece decreases with the increase of the number. Depending on the complexity of the parts, it may be cheaper to produce hundreds of parts using plastic injection molding.

How long can the plastic mold last?

These customized plastic injection molds will typically last more than 100000 cycles. In addition, ddprototype provides a lifetime warranty for these production injection molds. As long as we continue to manufacture parts for you, we will maintain and refurbish the tools at our own expense as needed.

With DDPROTOTYPE, design changes can be made on the production mold. Our engineer will coordinate with you to change the CAD file and rework the mold accordingly. Before production, you will receive the modified samples for your approval.

What you need to know when purchasing injection mold

Ddprototype provides a full range of injection moulds, which will be exported from our wholly owned manufacturing plants in China for you to run in your own factory or designated production plant. Molds for plastics will be designed and manufactured in accordance with us / Western standards. It will be optimized for production on your injection molding machine, with details including cooling line connections ready for your existing setup. The typical steel grades of these dies are 718 / 718H, S136 / s136h, nk80 or as required by the customer.

Different customers have different mold requirements, so we can make it according to your plastic mold injection system specifications, including steel, hot runner system, process, surface polishing or plastic texture of injection mold. We can also meet your functional requirements for mold and injection molding, and match production specifications and mold design. After the completion of the mold, trial production and short-term production can be carried out, for example, to close the gap of the production mold.

Die durability

In the process of injection molding, the stress of injection mold is very large. The mold will wear as time goes on and over and over again. There are many factors that can extend the life of the injection mold, such as the use of higher grade, more durable steel. Similarly, injection molds are designed for specific pressures and temperatures. Operating the injection mold outside these ranges can shorten its service life. At icomold, we offer a lifetime warranty for production molds. As long as you continue to let us shape the parts for you, we will repair, renovate or even replace the mold when necessary, and the cost will be borne by us.

Make sure your injection mold is designed correctly

Considering more complex injection molds, it is important not only to make them to specifications, but also to design them correctly. There are so many injection molding machines in the world that their design capabilities are different. A company with many years of experience and knowledge needs to ensure that the injection mold can work properly. For example, home molds (molds that make more than one part at a time) need to be properly balanced. If the home mold is not made properly, you can get some short shot (unfinished) or parts with burr in the mold. Flash can be particularly harmful because it may require additional manufacturing time to trim parts.

Beware of buying directly from overseas

Trying to cut costs by buying directly from overseas may be tempting, but there may be some problems. Language and time difference are two problems. Due to language barriers, it may be difficult to communicate, and different working hours may lead to project delays. At iconold, we adopt the best of both worlds business model. You can work directly with an American company and save money because of the low manufacturing cost structure of our wholly-owned Chinese factory. You will be working with an English speaking project manager in Holland, Ohio, so it’s easy to talk to them and maintain normal working hours.

Another problem you may encounter directly with foreign injection molding companies is poor quality. However, since we have our own manufacturing plant in China, our internal quality assurance team can ensure that you will get the highest quality injection mold.

Production of injection molding parts

When we do produce injection molds directly to our customers, we can also produce our own plastic parts in our manufacturing plant. Our lifetime warranty will benefit you when molding parts. As long as we run the parts for you, we will maintain, repair and even replace your molds when necessary, at our own expense.

The post Mass Production Injection mold appeared first on DDPROTOTYPE.

Injection Mold Manufacturer In China

Martin.mu — Fri, 31 May 2024 09:50:53 +0000

DDPROTOTYPE is a top injection mold manufacturer in China. There is a stigma that China’s injection molding manufacturers and molds are of poor quality, made of substandard materials. Although some suspicious companies may cut corners, we don’t have them in ddprototype. We only use high-quality metal, fully meet the American or European injection mold standards. In fact, we have a lifetime mold warranty for the molds we produce in the factory. As long as we run the parts in the manufacturing plant, your mold has a lifetime warranty and is subject to the terms and conditions of DDPROTOTYPE.

Our injection molding and manufacturing advantages

DDPROTOTYPE is a Hong Kong based injection molding manufacturer with high-quality, low-cost production facilities in China and well-educated skilled personnel. One of the advantages we have over “China direct” injection molding companies is that you have no language barrier. You will work with an English speaking project manager who will provide engineering support, customer service and handle your injection molding projects in China from the beginning to the end.

No need to worry about the time difference, whether you need a quick email reply or a telephone discussion, we will provide you with timely help and ensure that your injection project is carried out as planned.

Since 2003, we have been focusing on the plastic injection molding business. We understand the challenges of working directly with molders in China and our hybrid business model addresses these issues. At ddprototype, our Chinese injection mold manufacturing team and staff uphold high standards of work, combined with our project manager experience, engineering support and customer service, to ensure that your parts can be manufactured in time and with high quality.

We are responsible. You don’t have to worry that some shady offshore companies will take money and leave poor quality products. We have a wholly-owned factory in Shenzhen, China. We can control the quality of injection moulds while reducing the production cost. That’s why we insist on providing lifetime mold warranty.

We support American manufacturing

From time to time, we communicate with customers who only want to do business with plastic injection molding manufacturers with factories in the United States, and we respect that. But they usually pay more than we do. Due to our low cost structure in China, we are able to offer lower prices for injection moulds and plastic parts. We also offer solutions for people who want to make in the United States rather than in China – our Chinese mold manufacturing team will produce “export molds” and ship them to customers’ designated manufacturing plants in the United States.

Your project is protected by US intellectual property law

There have been reports of unethical Chinese companies infringing customers’ IP and legal rights. As a U.S. company, ddprototype maintains confidential information of its customers in accordance with U.S. law. We are committed to protecting our customers’ IP. Whether it’s personal / company information, CAD files, quotations or orders, we will keep the customer’s proprietary / confidential information confidential. To learn more about intellectual property protection, visit our terms and conditions page.

Combine the best of both worlds

We have been very successful in the “best of both worlds” business model, and continue to work with customers seeking lower cost value of customized plastic injection molding in China. Lower cost, higher quality, and no attempt to deal directly with offshore manufacturers. Check out our instant quote system to see what we really can afford.

You can rely on the quality of plastic manufacturing

Customers are very important to us. As a leading manufacturer of injection moulds, we have the responsibility to ensure that our products are of the highest quality and affordable prices to our customers. Our customers cover many different industries, and we have extensive experience and track record to provide the level of detail required by each industry.

Here are some more of the industries that we have experience in:

Pharmaceuticals
Telecommunications
Industrial & Transportation
Consumer Electronics
Consumer Products
Appliances
Sporting
Energy

Injection Molding Can Be Used in Any Industry

Plastic injection molding (PIM) is an economical way to manufacture a large number of customized plastic parts. One of the main questions we encountered at DDPROTOTYPE was “which industries benefit most from plastic injection molding?”

Answer: almost all manufacturing.

Whether you are in the automotive, medical or construction industries, your business can benefit from injection molding. The versatility of design molds can create parts of various sizes, shapes and sizes, enabling us to mass produce the parts needed to make your business successful.

Here are just a few items we can produce for these popular industries

Automotive

– Fluid tanks
– Trim parts
– Door handles
– Caps for tanks
– Engine covers

Medical

– Catheters
– Syringes
– Inhalers
– Cases
– Machine covers

Packaging

– Crates
– Handles
– Dividers
– Lids
– Buckets

Consumer Products

– Dials
– Buttons
– Doors
– Hinges
– Holding tanks

Bring your invention and business to life with injection molding

Whenever you have a great product idea, your goal is to create it to improve the lives of others. In many cases, plastic injection molding can help you achieve this goal. Whether you want to mass produce a simple handle to make your product easy to move, or to create a pump that is critical to the operation of the device, custom plastic molding can bring your idea to life. By working with ddprototype engineers, you can create the perfect injection molding parts to make your products fully functional. We offer a variety of plastics for you to choose, which can help you choose the best materials to maximize the function of the invention.

In addition to turning your ideas into reality, mass production of customized plastic injection parts is fast and cheap. We can help you produce thousands of parts in a short time and save you money. In this way, your products will be affordable to customers without damaging your profits. Many companies come to ddprototype and their products need multiple plastic molds. Our engineers can process more than one plastic mold at a time, so you can get all the parts you need at the same time.

The post Injection Mold Manufacturer In China appeared first on DDPROTOTYPE.

Insert Injection Molding

Martin.mu — Fri, 31 May 2024 06:07:00 +0000

What is insert injection molding?

Insert molding is a process that begins by putting metal, ceramic or plastic parts into plastic injection molds. After these parts are properly placed, the mold is filled with molten plastic during the normal injection molding process. After the plastic has cooled, the inserted part is now firmly bound to and integrated into the plastic part. There are many options for placing inserts in the mold. Threaded sleeves, wires, batteries and warning labels are just a few examples.

Why use insert molding?

One of the biggest reasons for using insert injection molding is the total cost savings. Although it is more expensive to add inserts in the production process, there is no second processing of the parts to manually install the inserts, which can save a lot of costs. Another advantage is that the insert is more structurally stable than inserting it after molding.

Consider a plastic part in which multiple threaded bushings need to be integrated. If these bushings are not insert molded during plastic injection molding, they must be added in other post molding processes by other methods (e.g., hot riveting (thermoplastic riveting)). This second process will increase the time and cost of molding projects.

Metal insert molding

The final benefit to consider is that weight savings can be achieved through insert molding. For example, if you consider making a part entirely of metal because it requires machining metal screw holes, you can save a lot of weight by using plastic injection molded parts and inserting threaded metal bushings (assuming your design will allow this material variation). This is very important in industries where weight reduction is a top priority, such as the automotive and aerospace industries.

Is there any special consideration for insert molding?

Support

Whether you use metal, ceramic or plastic inserts, one of the biggest considerations is that you have enough material to support the plug-in. Too thin a wall can cause the insert to separate from the rest of the part. This may occur during production or during the use of parts. You need to make sure you have enough plastic material to place the plug-in correctly.

Temperature

When using plastic inserts, this consideration is more of a problem. You are going to make sure that the inserts you use in the mold can be safely exposed to the temperature required to melt the plastic injection material without deforming the insert. If your insert cannot withstand the temperature of the molten plastic, you will need to see if another plastic with a higher melting point can be safely used.

Pressure

Another consideration for insert molding is whether your insert can withstand pressure. The pressure generated in the process of plastic injection molding is very high. You need to make sure that the blade can withstand this pressure without breaking or deforming.

Injection molding process of insert

Insert molding (also known as insert molding) is similar to injection molding and uses the same type of machine. During the molding of the insert, the plastic resin particles are heated until they melt. The molten liquid plastic is introduced into the mold under pressure. The die can be made of any metal such as steel or aluminum. The molten form is then cooled and solidified into a solid form. The plastic material thus formed is then removed from the mold.

Insert molding also uses materials similar to the injection molding process. The only exception is metal elements that can be added before the mold is finished.

Insert Molding Applications

There are many applications to insert molding. Such applications include:

Auto industry components
Industrial equipment components
Medical devices
Couplings
Threaded fasteners
Electrical parts

DDPROTOTYPE can help you with your insert molding needs.

Insert molding and Overmolding

On the surface, the two technologies look very similar. Insert molding usually takes only a small part and is then encapsulated in a plastic resin, just like a threaded bushing. Overmolding, on the other hand, is a process in which plastic is injected into another top, a different material, a plastic sheet forming a plastic layer. For example, the case of a portable drilling rig. The main body of the shell is the first process of injection molding (base material), and then the softer handle and handle are coated on the main body.

How long can the injection mold last?

Our injection molds usually last more than 100000 cycles. In addition, DDPROTOTYPE provides a lifetime warranty for these injection molds. As long as we continue to manufacture parts for you, we will maintain and refurbish the tools at our own expense as needed.

The post Insert Injection Molding appeared first on DDPROTOTYPE.