Manufacturing Services: Plastic injection molds making & molding
Part Material: PA-MXD6-4511-BK
Part Name：BOTTOM BASE for ATM
Shrinkage：1.0035
Cavities: 1X1
Size:43.9*133*258
Tool Material: NAK80
This customer invests and establishes an overseas manufacturing company in the southern region of China.
"In JBR we found the right partner for the production of this part. JBR supported us in the feasibility study of the designed product, the production of the production molds as well as the parts. The customer experienced this process as a real collaboration. The proactive working method and in-depth technical expertise of JBR helped us make the mold that meets the excellent quality requirements that we sets for all its products. JBR continuously thought along in the process, gave us fast delivery times and complied with all agreements."
Design for Manufacturing (DFM) review is a critical step in the product development process where the design of a product is assessed for its manufacturability. The goal is to ensure that the design can be efficiently and cost-effectively produced at scale without sacrificing quality or functionality.
With Design for Manufacturing review，we could avoid causing molding defects, so that’s always our first priority to address. We also find that at this level of details we can help the customer to find or make minor improvements that they may have overlooked, so now is a great time to implement them.
We worked with the customer to understand the critical tolerances or other dimensions that could not be modified and then worked within those constraints. We then prepared a power point file to share with the client, highlighting the most important areas for their feedback or comments.
Draft angles play a vital role in the successful molding of parts and should be carefully considered during the design phase to optimize manufacturability and part quality.
Draft angles prevent the part from getting stuck in the mold by providing clearance for easy release. Without proper draft angles, the part may experience drag or friction against the mold walls, leading to deformation, surface defects, or even damage to the mold itself.Clear communication between designers and mold makers is essential to ensure that draft angle requirements are understood and implemented correctly in the mold design. Collaboration throughout the design and manufacturing process helps prevent costly errors and delays.
To locate potential sink marks we did a wall thickness analysis with Mold flow. It calculated those areas most likely to create sink due to unequal mass distribution. The areas marked in yellow show where a sink mark is likely to be, because there is an extra structure on the inside of the part that adds mass. In this case it’s unavoidable without a major re-design so the customer chose to accept the results.
The line of draw is the direction in which the two halves of the mold open and close. It defines how the part can be removed, and also shows where a parting line mark will be left over on the finished piece.
The direction of the tool opening not only affects the parting line but also the location and orientation of other components and features such as sliders and inserts, ejector pins and coolant lines.
Ejector pins are essential components used in injection molding processes.
They come in various shapes and sizes depending on the complexity of the part being produced and the design of the mold. They play a crucial role in ensuring the efficient production of high-quality molded parts.
They push the part off the core after molding, but leave a corresponding mark on the part surface. We had to be careful to place the pins in a balanced arrangement to ensure even distribution of force to avoid damaging the part or the pins themselves. We also needed to place pins strategically around the gate, where sufficient ejection pressure is needed to clear the gate in the event of a partial injection, or “short shot”.
Throughout the entire mold tool design process, collaboration between designers, mold makers, engineers, and manufacturers is crucial to ensure that the final mold meets all requirements and specifications for successful injection molding production.
We hope that in this case study you were able to find useful information that can help you prepare your product designs for your next rapid prototyping or volume production order. We will apply the same careful Design for Manufacturing review when we help you bring your product ideas to life, so let’s get started today!
