Mold Trial Service

Ming-Li Precision offers comprehensive precision mold trial services, ensuring top-quality mold performance and reliability before mass production. Our advanced technology and extensive expertise guarantee detailed mold testing and validation to meet the highest industry standards.

 

Ming-Li Precision Mold Trial Capabilities

 

1. Advanced Mold Testing

Our cutting-edge testing facilities and precision tools are designed to rigorously test each mold, ensuring that every component meets the highest standards of accuracy and functionality.

•         •  Equipment: Cutting-edge testing facilities and precision tools.
•         •  Procedures: Rigorous testing protocols to ensure mold accuracy and functionality.

 

2. Detailed Validation Process

We conduct thorough inspections using high-precision measurement tools and detailed analysis of mold performance. This helps identify potential issues and areas for improvement before mass production.

•         •  Inspection: Thorough inspection using high-precision measurement tools.
•         •  Analysis: Detailed analysis of mold performance and potential improvements.

 

3. Custom Solutions

We offer tailored trial services to meet the specific requirements of each customer, providing comprehensive reports on mold performance and quality to ensure satisfaction.

•         •  Customization: Tailored trial services to meet specific customer requirements.
•         •  Documentation: Comprehensive reports on mold performance and quality.

 

Benefits of Precision Mold Trial Services

 

•         •  High Precision: Ensuring tight tolerances and accuracy in mold performance.
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•         •  Superior Quality: Validating mold quality to meet stringent industry standards.
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•         •  Risk Mitigation: Identifying and addressing potential issues before mass production.
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•         •  Cost-Efficiency: Reducing the risk of production delays and costly rework.

 

Applications in Various Industries

 

•         •  Aerospace: Validating molds for turbine blades, structural parts, and more.
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•         •  Medical Devices: Ensuring quality molds for surgical instruments, implants, and diagnostic equipment.
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•         •  Electronics: Testing molds for connectors, micro-components, and housing parts.
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•         •  Automotive: Validating molds for engine components, sensors, and intricate mechanical parts.
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•         •  Industrial: Precision mold testing for manufacturing processes.
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•         •  Consumer Products: Ensuring quality molds for household items and consumer electronics.
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•         •  Telecommunications: Validating molds for connectors, housing, and other components.
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•         •  Energy: Testing molds for components used in energy generation and storage.

 

 

Ming-Li Precison Mold Trial Prcoess

 

The mold trial procedure is a critical step in the injection molding process, ensuring that the mold functions correctly and produces high-quality parts. This process involves several stages, each designed to optimize and validate the mold before full-scale production begins. By following a structured approach, manufacturers can identify and resolve potential issues early, thereby reducing production costs and improving efficiency.

 

 

 

1. Material Preparation

•         •  Objective: Ensure that the material required for the mold trial is adequately prepared and available.
•         •  Actions:
  •                 Purchase the required plastic material.
  •                 Verify the stock to ensure sufficient material for the trial.

 

2. Mold Inspection

•         •  Objective: Confirm that the mold is in proper condition for the trial.
•         •  Actions:
  •                 Check previous parameters used.
  •                 Inspect the mold structure and runner system.
  •                 Ensure the material is dry and ready for use.

 

3. Mold Installation

•         •  Objective: Set up the mold correctly in the injection molding machine.
•         •  Actions:
  •                 Install the mold in the machine.
  •                 Check and set the mold temperature.
  •                 Set the injection location according to the mold design.

 

4. Molding Parameter Initial Setup

•         •  Objective: Identify potential issues under different injection conditions.
•         •  Actions:
  •                 Set a low locking force (±5 bar) to start.
  •                 Maintain back pressure below 200 bar.
  •                 Set the filling pressure to 30% to begin the injection process.
  •                 Determine and set the suitable switch point.
  •                 Ensure there is enough forcing time during the process.

 

5. Molding Parameter Optimization

•         •  Objective: Enhance the production efficiency and reduce costs.
•         •  Actions:
  •                 Optimize clamping force to prevent defects and reduce wear.
  •                 Adjust injection speed and pressure to achieve the desired part quality.
  •                 Optimize cooling time to ensure proper part formation and cycle time efficiency.

 

6. Molding Condition & Mold Trial Problem Record

•         •  Objective: Document and address any issues that arise during the mold trial.
•         •  Actions:
  •                 Record all injection parameters used during the trial.
  •                 Document any problems or deviations observed.
  •                 Analyze and adjust based on recorded issues to refine the process.

 

7. Sample Fabrication

•         •  Objective: Produce samples for thorough testing and validation.
•         •  Actions:
  •                 Fabricate mold trial samples.
  •                 Conduct tests to ensure samples meet required specifications and quality standards.
  •                 Provide samples to stakeholders for confirmation and further evaluation.

 

Completing a mold trial process effectively ensures that any potential issues are identified and resolved before moving to full-scale production. This meticulous approach helps in maintaining high-quality standards, optimizing production parameters, and reducing overall manufacturing costs. By adhering to these steps, manufacturers can achieve a smooth transition from trial to production, ultimately ensuring customer satisfaction and product excellence.

 

 

Main Steps and Precautions for Injection Mold Trial

 

Before the new mold injection molding or when the machine is replaced with another mold for production, mold trials are an essential part of the process. The success or failure of the mold trial directly impacts whether subsequent production in the factory will proceed smoothly. Therefore, reasonable operating steps must be followed during the mold trial, and useful technical parameters recorded, to facilitate mass production.

 

Precautions Before Mold Trial

 

1. Understanding Mold Information:

   • It is best to obtain the mold design drawings for detailed analysis and arrange for the mold technician to participate in the mold trial work.
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2. Checking Mechanical Fit on the Workbench:

   • Pay attention to any scratches, missing parts, or looseness. Check if the slider movements of the mold are accurate, if there are any leaks in the water and air pipe connections, and if the mold opening stroke is limited, it should be marked on the mold. These actions, if done before hanging the mold, can avoid the waste of time spent dismantling the mold if problems are found after hanging it.
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3. Choosing the Suitable Injection Molding Machine:

   • Ensure:
     • •  The maximum injection volume of the machine.
     • •  The mold fits within the tie bar distance.
     • •  The maximum moving stroke of the platen meets the requirements.
     • •  All relevant tools and accessories for the mold trial are ready.
   • Once everything is confirmed, proceed to hang the mold. During hanging, make sure not to remove the lifting hooks before all the platens are clamped and the mold is opened, to avoid mold dropping due to loose or broken clamps. After installing the mold, carefully check the mechanical actions of all parts of the mold, such as the sliders, ejector pins, unscrewing mechanisms, and limit switches. Ensure the nozzle and the sprue are aligned. During mold closing, adjust the clamping pressure lower and check for smooth movements and abnormal sounds during manual and low-speed mold closing. Adjusting the alignment of the nozzle and sprue using test paper can be challenging but essential.
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4. Increasing Mold Temperature:

   • Use an appropriate mold temperature controller to raise the mold temperature to the required production temperature based on the material properties and mold size. After the temperature is raised, recheck the movements of all parts, as thermal expansion of the steel might cause mold sticking, leading to scratches or chatter marks.

5. Adjusting Trial Conditions One at a Time:

   • If the factory does not implement experimental plans, it is advisable to adjust only one condition at a time to differentiate the effects on the product.
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6. Pre-drying the Material Appropriately:

   • Ensure the raw materials are properly dried based on their characteristics.
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7. Using the Same Material for Trial and Mass Production:

   • Try to use the same material for the trial and future mass production.
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8. Avoid Using Secondary Materials for Trials:

   • If there is a color requirement, arrange for color matching during the trial.
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9. Handling Internal Stress Issues:

   • Address internal stress issues affecting secondary processing by performing post-trial secondary processing once the product has stabilized. Adjust mold clamping pressure and check for uneven clamping pressure to avoid product flash and mold deformation.

After checking all these steps, adjust the clamping speed and pressure to normal, set the safety locks, and adjust the ejection stroke. If a limit switch is involved in the maximum stroke, shorten the mold opening stroke and cut off high-speed mold opening action before the maximum stroke. This is because high-speed actions take up a longer stroke than low-speed ones. Ensure the mechanical ejector rods in the plastic machine operate after the full-speed mold opening action to avoid deformation of the ejector plate or stripper plate.

 

Key Steps of Mold Trial

 

To avoid unnecessary waste of time and troubles during mass production, patience is required to adjust and control various processing conditions. Find the best temperature and pressure conditions, establish a standard mold trial procedure, and use it for daily operations.

1. Check the Plastic Material:

   • Ensure the material in the barrel is correct and has been properly pre-dried. Using different materials for the trial and production might yield different results.
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2. Clean the Barrel Thoroughly:

   • Prevent degraded or mixed materials from entering the mold. Degraded materials can cause the mold to seize. Check the barrel temperature and mold temperature to ensure they are suitable for the processing material.
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3. Adjust Pressure and Injection Volume:

   • Aim to produce visually satisfactory products without flash. Avoid adjusting too quickly as slight changes in filling rate can significantly affect the filling process.
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4. Allow the Machine and Mold Conditions to Stabilize:

   • Even for medium-sized machines, wait at least 30 minutes. Use this time to inspect the product for possible issues.
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5. Screw Advancement Time:

   • Ensure it is not shorter than the gate solidification time to avoid weight reduction and performance loss of the product. Adjust accordingly as mold temperature increases.
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6. Reduce Total Processing Cycle Time Reasonably.

7. Stabilize New Conditions for at Least 30 Minutes:

   • Produce at least a dozen continuous full mold samples, label them with date and quantity, and place them by mold cavity for testing stability and deriving reasonable control tolerances (especially valuable for multi-cavity molds).
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8. Measure and Record Important Dimensions:

   • Measure after the samples have cooled to room temperature.
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9. Compare the Dimensions of Each Sample:

   • Check:
     • •  Product size stability.
     • •  If certain dimensions increase or decrease, indicating changing processing conditions such as poor temperature or hydraulic control.
     • •  If the dimensions are within tolerance.
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10. Check Individual Cavity Products:

    • If the product sizes do not fluctuate and processing conditions are normal, observe if each cavity's product quality is acceptable and within allowable tolerances. Note the cavity numbers with continuous over- or undersized products for mold dimension verification.

 

Recording Parameters During Mold Trial

 

Record and analyze data for modifying molds and production conditions and for future reference during mass production.

1. Extend Operating Time:

   • Stabilize melt temperature and hydraulic oil temperature.
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2. Adjust Machine Conditions:

   • Based on product dimensions. Increase gate size if shrinkage is too large or the product shows insufficient injection.
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3. Correct Over- or Under-sized Cavity Dimensions:

   • Adjust machine conditions such as filling rate, mold temperature, and pressure, and check if certain cavities fill slower.
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4. Check and Correct Machine Failures:

   • Machine issues like faulty oil pumps, valves, or temperature controllers can affect processing conditions. Well-maintained molds cannot perform efficiently on poorly maintained machines.
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After reviewing all recorded values, retain a sample set for comparison to verify improvements. Properly store all records from the mold trial, including cycle time, various pressures, melt and mold temperatures, barrel temperature, injection action time, and screw feeding time. These records will help establish consistent processing conditions for producing quality products.

Currently, factories often overlook mold temperature during mold trials, although it is crucial for future mass production. Inaccurate mold temperatures can affect sample dimensions, gloss, shrinkage, flow marks, and underfill issues. Not using a mold temperature controller can lead to difficulties in future production.

 

Further Reading

For those interested in diving deeper into the latest technologies and trends in mold trial, the following resources offer comprehensive insights:

 

► What is the principle of plastic injection molding (plastic molding process)?

        ► Wha is the essential for Injection Molding Stability - the Venting & Flow length ratio?

                 ► Wha is the essential for stable plastic injection molding - material temperature?

                          ► Wha is the essential for Injection Molding Stability - Injection Speed?

                                    ► Wha is the essential for Injection Molding Stability - mold temperature?

                                            ► Wha is the essential for Injection Molding Stability - Gate?

                                                      ► How to solve the short shot issue for plastic injection molding?

                                                                 ► How to solve the burr and flash issue for plastic injection molding?

                                                                             ► How to solve the flow mark issue for plastic injection molding?                                                                           

                                                                                          ► In-Depth Overview of Injection Molding Parameters

 

 

Why Choose Ming-Li Precision?

Ming-Li Precision stands out due to its commitment to quality, advanced technology, and customer-centric approach. Our precision mold trial services are designed to ensure the highest level of performance and reliability, giving our clients confidence in their production processes.

 

Know more our mold trial service, please contact us.