After collaborating with the toolmakers on the design, the part is ready and approved for the T1 sampling stage. They will build the first tool with a 2-16-week lead time dependent on design considerations. T1 sampling demonstrates that the tooling functions correctly and produces ideal parts. After the T1 sampling is accepted, any necessary modifications and aesthetic mold texturing can begin. These additional modifications can take 1-2 weeks to complete. The modified molds, referred to as T2 samples, are sent for approval of texture and appearance. Once the T2 samples are approved, the toolmaker releases them to the contract manufacturer.
Once with the manufacturer, the T2 samples are placed into the production line for process development and part qualification. The tooling undergoes a series of molding studies that help outline the optimal conditions and characteristics for creating parts using that tool. The manufacturer runs experiment trials to isolate process inputs and corresponding impacts on part characteristics. This initial testing helps the molder validate an ideal processing window that produces parts within specification.
After initial process development, qualifications, and validations, the tool enters a regular production maintenance schedule. Here the tool is regularly monitored for wear and other potential issues affecting part quality or tooling lifetime.
Learn the terms used in the mold-making & injection molding industry, and their definitions in our glossary.
A cosmetic defect caused by shear through the gate.
An injection mold tool used to supply parts while the production tool is being built.
Pins or protrusions in the tool that are inserted to produce critical dimensions or features.
The angle or taper provided on molding sections to facilitate the removal of the molded piece part from the mold.
Steel pins strategically placed in the mold used to push or eject the finished piece part from the mold.
One mold that shares two or more different parts in the core and cavity for injection molding.
A rounding of an interior or exterior corner of a part design.
A thin fin of material which forms at the parting line of the mold.
Flaws or visual blemishes that indicate material flow direction in the mold.
A mold defect when the metal mold material creates friction upon itself from rubbing.
An opening in the mold where the injection-molded material enters the mold to create the intended plastic part.
This is a manual slide. A hand pick out is used to produce details such as undercuts and recesses on low-volume runs to reduce overall tooling cost.
This gate allows material to flow directly into the part with no runner. It does not need to be trimmed. This gate is usually used for multi-cavity tools with high-volume runs. There is a heater wrapped around the gate to keep the material fluid so it can fill a cavity. In a hot tip, the material is shot through a gate opening between .040. and .120.
Pins located in one half of the mold assembly, mated with bushings in the other half and used to align the two portions of the mold base.
A tool that is built for volumes that do not require the additional costs or lead times of production tooling.
Creating functional parts from plastic in volumes in upwards to 40,000+. LVIM produces parts with quality and accuracy produced by normal production tooling, but with shorter lead times.
(Master Unit Die) Inserts which are quickly changed over by using a standard frame.
Flaws or visible blemishes where two material flow fronts meet.
The act of taking an object and placing it into a cavity of a mold and injection molding around this object to create a multiple material product.
A line or mark on the piece part indicating where the two halves of the mold meet.
Rounded edges or surfaces that allow plastic parts to be created in the injection mold.
An injection mold that is built quickly and cost effectively for low quantities. These spec material parts are used for functional testing and low volume production.
A groove or channel cut into either one or both halves of the mold which carries the molding material to the cavities.
The action of the material fluctuating when it is heated up and cooled down into the mold.
A shallow depression defect caused by thick wall sections. The material retains heat and shrinks more than normal due to irregular wall thickness.
A portion of the mold which is made to travel at an angle to the normal movement of the molding machine, to produce recesses, undercuts and holes.
Usually a term meant for RTV Molding, but also used for aluminum tooling for plastic injection molding compared to steel. Although, aluminum has been proven as a reliable mold material for production injection molding.
A cosmetic defect caused by moisture in the resin or injection molding machine screw rotation or the movement of material through a curved area.
The round, tapered material, which connects the loading chamber or nozzle with the runner system or the piece part.
This gate goes directly into the part with no runner.
A gate that is directly off the runner into the part. A tab gate needs to be trimmed in a second operation after the plastic part is ejected.
A gate that allows the material to flow into the plastic part. But when the part is ejected, the opening mold shears off the gate. (No second operations).
A recess or depression in a molded article, located in such a position that it impedes or makes impossible the ejection of the part by the normal opening of the molding machine.
A shallow groove or slot machined into the parting line of the mold which allows air and gases to escape from the cavity as it is being filled with the molding material.
Dimensional distortion in a molded part caused by material shrinking in different ways.