We are all familiar with die casting, which is a process that involves injecting molten plastics at very high pressure into a metal mold called a die, and then solidifying it. Liquid plastics will solidify when cooled and will take on the shape of the die as it solidifies.
We rely on castings for many of our day-to-day needs. Pesticides are used in a number of things and places around you, including appliances at home, cars you drive to work, office machines, mobile phones, skin-care products, clothes you wear, and much more.
This blog explores the steps that a buyer seeking plastic molding services must take to ensure that they receive a final product that meets their specifications. Moreover, as one of China’s top injection molding companies, Topworks is better equipped to connect you with reliable manufacturers and factories located in die casting’s global capital. Collaboration plays an essential role in the success of your sourcing process.
Files in 3D format are important
It is necessary to create a 3D model for the development of a product. When it comes to simple products, 2D drawings can be used to show basic dimensions, weights, and tolerances. Tolerances are allowed variations in dimensions. Any intricately designed part will require a 3D file’s of 3D files. One such format is STEP. Your 3D file doesn’t need to be in a specific format. The manufacturer will then receive the 3D file. In turn, the manufacturer will tell if and how much each part will cost, as well as whether it is possible to produce the part and extract it from the tool without problems.
We also receive samples and design files from some of our customers. It may be necessary to use samples to highlight defects in the design or perhaps to emphasize certain aspects of the surface finish so as to make improvements.
As a starting point, we need a 2D drawing that shows essential information, such as the materials, finishes, and tolerances. The final intended use of the product, for example, or the type of environment it will be used in (such as in an environment that is corrosive, humid, or vibrates a lot) are also helpful details.
Additionally, it helps to know if the product has a history of breaking, cracking and distorting under certain conditions. When a die cast aluminium part is fabricated and machining, it is perfect. But when it is powder coated and surface treated, it becomes distorted.
Considering such details allows us to improve our manufacturing process. If the buyer wants to specify a specific material, wall thickness, or surface finish, they must be as specific as possible. The manufacturer will be able to better understand the requirements.
Tooling is important, but what is it?
It’s crucial to design the right tool. Customers sometimes request tools be made in a specific way for a specific reason. However, toolmakers are generally responsible for designing the tools. Making a tool is called tooling. Furthermore, jigs, fixtures, mold inserts, and cutting tools may be used in addition to dies. An electrical discharge machining technique is one of the most common machining processes in tooling. The process involves cutting and shaping metal with electric sparks. The tools are then heated and, if needed, the surface texture is added.
Consider these points when designing tools:
A tool must be able to withstand harsh conditions such as high temperatures and wear and tear, as well as corrosion. The materials also need to be thermally conductive and both flexible and ductile (meaning that they can withstand tension without breaking).
Therefore, if they are to last, they need to be constructed from the highest-grade tool steel, even if it is more expensive than regular steel.
They will last for a long time. You can expect them to last up to 70,000 cycles. Sometimes as long as 100,000 cycles. But the life of a tool also depends on its material, its cost, the material it is injected with, and the structure it is cast in.
Time to production:
Building a production tool takes, on average, 20-60 days. The surface finish or texture of the tool can greatly affect the lead time. Budget accordingly.
According to your needs and size, tooling costs can be as low as a few hundred dollars, or as high as hundreds of thousands of dollars. If you are considering which manufacturer will offer you the cheapest tooling cost, you might be tempted to go with them.
Nevertheless, if you want to save time in the long run, it’s better to invest in a tool that is built to last and ensure that it receives regular maintenance.