Perfect Parts the First Time
Next Chapter Manufacturing
Tooling to Production Simplified: The most efficient tooling in the industry
In the world of injection molding, perfection often seems elusive. The quest for flawless parts, devoid of defects like gas traps, has been a continuous journey for Molders and Mold Makers alike. But what if achieving perfect parts right from the first shot is not only possible but can also lead to substantial cost savings? In this month's newsletter, we explore how striving for perfection can revolutionize your molding processes and your bottom line.
Moldmakers: Mastering Mold Venting and Eliminating Gas Traps
As a Moldmaker, your responsibility lies in crafting molds that not only produce high-quality parts which means that you are responsible for providing a mold that not only properly vents but will remain vented for the life of the mold. Gas traps can lead to an array of issues, from cosmetic defects to structural weaknesses to weak knit lines in molded parts. This feature article dives deep into effective mold venting techniques and strategies to help Moldmakers create molds that set the stage for perfect parts.
Molders: Running Production Defect-Free
Molders, your role in the quest for perfection is equally crucial. Running production defect-free means reducing scrap, minimizing rework, and delivering consistent, high-quality parts. Imagine the cost savings when your first shots to the last shots are defect-free without constantly pulling the mold to clean vents. In our newsletter, we provide insights into achieving flawless production runs, highlighting the financial benefits of doing it right the first time.
The Solution
Working on both the tooling and processing side, I've never been able to make good parts off a bad mold, and I'm sure you haven't either. That's why, at Next Chapter Manufacturing, we've perfected crafting precision venting alongside conformal cooling and other vital details of a mold to make it run exceedingly well for the life of the program.
The Problem With Venting
Venting molds is extremely challenging because you must create a gap in the molding surface large enough for the gas to escape, but small enough so plastic does not leak out.
As molds get more complex, effectively venting a mold becomes more challenging. It is becoming more frequent that I see that an injection filling simulation of a part will racetrack around the perimeter and block off all of the parting line vents. this leaves the majority of the venting for some type of internal splitting or sub-inserting that can be expensive to fabricate. Mold flow simulation is a good indication of where gas traps will occur, but the locations identified are not always?ideal for venting. Imagine being able to have 500X the venting of what you would with split inserts of ejector pins. Would that eliminate gas traps for good?
The Solution is the New Standard
Next Chapter's InnoVent Technology makes it possible to precisely change the density of steel (down to .001") in specific areas to produce micropores that let the gas out in abundance while creating a seal off for the plastic not to flash. this means that you can place a vent exactly where you need it and the rest of the insert can be full solid steel for optimal wear and conformal cooling integrated. In short, by using variable density 3D printed inserts, a mold builder can eliminate the most challenging gas trap defects in high-wear molds which means perfect parts first shots.
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The Cost of Imperfection
We break down the financial implications of defects in injection molding. Explore how defects affect the bottom line. Understanding the true cost of imperfection is the first step toward achieving perfection and substantial cost savings. Consider an?example case study from a project we did recently, a custom injection molder with a four-cavity?mold running 500k shots per year incurs the following?unnecessary costs:
Venting Where You Need it Most
If you want to learn more about this and how to mold perfect parts with first shots, consider registering for our webinar on November 3rd at 11 a.m. EST.
We will cover best practices world-class molders use to be successful with InnoVent Technology and how to properly maintain this technology over the life of the program with ease.