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Rapid Tooling for Plastic Injection Molding

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Fabrication of conventional hard tooling. significant fixed cost. considerable fabrication time ... Fabrication. Indirect OR Secondary Fabrication ... – PowerPoint PPT presentation

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Title: Rapid Tooling for Plastic Injection Molding


1
Rapid Tooling for Plastic Injection Molding
  • Puvas Nandakwang
  • Amiteshwar Sidhu

2
Outline
  • Background
  • Project
  • Phase I
  • Hardware
  • Phase II
  • Problems
  • Solutions
  • Future Improvements
  • Conclusion

3
Background
  • Typical prototyping
  • cannot provide product characteristics associated
    with the end use material
  • difficult and expensive to produce many high
    quality RP parts for testing
  • Fabrication of conventional hard tooling
  • significant fixed cost
  • considerable fabrication time

4
Background
  • Rapid Prototyping

Indirect OR Secondary Fabrication
Direct Fabrication
5
Introduction
  • Rapid Tooling
  • Soft tooling method
  • Rapid Prototyping methods employed to make tools
  • Molds such as an injection mold or an RTV mold
    that are made using RP technology
  • Low Cost Simplicity!

6
Project
  • Phase I
  • Part Design
  • Tool Design (Die)
  • Selection of RP process
  • Phase II
  • Build Part
  • Finishing Operations
  • Injection Molding

7
Phase I Part Design
Back View
Front View
Issues Smooth Edges, Size and Functionality
8
Phase I Tool Design
Back View
Front View
Issues Negative of the Part, all Protrusions
on part are Cuts on tool
9
Phase I Selection of RP Process
  • SLA process was selected because of
  • higher strength
  • better surface finish
  • adequate temperature properties
  • Some Numbers
  • Glass transition Temperature 149-184F(65-90C)

10
Plastic Injection Molding Machine
11
Die, after mounted on the shoe
12
Ready for injection
13
Injecting Plastic
14
Phase II Final Products
15
Problems
  • Wrapping of Die Plates
  • - Flatness is lost
  • - Locations of holes undergo deviation

16
Problems
  • Machining Operations
  • Face Milling done to restore flatness
  • Drilling to align mounting holes
  • Design Changes
  • Increased die thickness
  • Removed mounting holes
  • Increased gate length
  • Changed shape of gates

17
Possible Improvements
  • Blue material cracks near the hole
  • Design change to facilitate easier access of
    flowing liquid to the section which cracks

18
Conclusion
  • Rapid Tooling facilitates
  • Quick production of tools
  • Visualization of problems that might arise in the
    injection molding die design and process
  • However deformation during the curing process
    requires to be fixed with machining. Extra volume
    which might be lost due to machining should added
    to the SLA part.
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