Thin Wall Mold

Product Description

Thin wall molding is a specialized form of conventional injection molding that focuses on mass-producing plastic parts that are thin and light, without structural compromise, in order to achieve material cost savings and shorter cycle times. Faster cycle times improve productivity and lead to lower costs per part,so thin wall injection molding is widely applying to lightweight food packaging

All star plast is experienced in making good thin wall product molds,each year we make more than 50 sets of thin wall molds,like plastic food container molds,IML thin wall molds.Becuase these products are thin wall and light weight,we focus on the precise milling on molds and good cooling system to shorter the cycle time. We have constant-temperature room for our high-speed CNC machines with the tolerance 0.02mm.To get the cycle times as short as possible,we will make the cooling channels close to the molding surface and use copper which is good at cooling.Usually for these molds steel we use H13 or S136 steel with the hardness HRC can reach 42-48,so we not only guarantee the cycle time,but also the mold life.For these molds we make each cavity and core independently.

There’re some basic requirements for thin-wall molded parts production. Some are:

Thin walls need special machines for their manufacturing. Machines with new technology and having various controlling functions. It should be capable of generating high speed and pressure for thin-wall parts. Machines should be reliable and strong enough for a long working process. It can hold up against the high pressure of the cavity and clamp tonnage.

• For successful thin wall molding, process parameters are of much importance. They play an important role in thin wall manufacturing. The parameter setting is narrow for the operating window. So the process should fine-tune for producing high-quality parts.
• Any difference and variation in time may cause problems for the quality of thin parts. It may cause flashing and short shots. So time should set and not vary during the operation. Some parts need 0.1 second time for their better production. Thicker wall section parts have a big operational window. It’s easy for thin-wall molding manufacturing and operation.
• Proper and regular maintenance is essential for the thin wall parts molding procedure. As high tolerance requires for thin wall mold. Any residue on the surface may become a problem for quality. The quality of multi-cavity mold can affect by improper and irregular maintenance.
• Robots use for stack parts and removing purpose in thin wall manufacturing. They use in food packaging. You must know how to operate robots and must have the necessary knowledge about them. It’s necessary for successful thin wall molding.
• To keep the surface temperature consistent. You can locate the non-looping cool lines direct in the core, and the cavity can block them.
• For maintaining steel temperature, it would be better to increase the cool flow. The difference between the return and the delivery coolant must be less than 5° to 10° F. It should not be more than these temperatures.
• Fast filling and high pressure required injecting the molten material into the cavity. It will help freeze it out. Suppose a standard part fills in two seconds. Then a 25% reduction in thickness needs a drop for 50% filling time in one second.
• Choose mold material that doesn’t take part in increasing mold wear. When this material will inject into the cavity at high speed. Because of the high pressure of the thin wall, strong mold should manufacture. Rigid steel and H-13 provide extra safety to the tooling of thin walls. You can use P20 steel for the conventional application.
• For minimizing cycle time, you can choose a heat sprue brush and hot runner. By reducing wall thickness, you can decrease 50 % cycle time. Careful and proper management recommend for the mold delivery system.
• You can’t get a fast life cycle with a thin wall. Mold cooling systems should optimize for acquiring the fast life cycle.
• Thin wall molding is more costly than other molding methods. You have to pay more for getting strong and reliable parts. A mold having poor design will break more quickly, and it can also be harmful to machines. So don’t compromise on quality to save money.

Proper and in-depth knowledge about injection molding troubleshooting is vital. It’s necessary for successful thin-wall parts molding. Only experienced people can’t give you quality assurance and reliability of parts. Wrong parameter setting and little faults can make molding worse. So selecting a skilled and qualified molding company is essential for you.

Besides we also make other food container molds,like ice cream box,conatiners using in refrigerator or kitchen,sandwich box mold,etc.

1. Mold Capacity
Stack mold is a good source that improves the output per capita. The clamp unit should be long and strong. So it can withhold the extra weight and stroke.

2. Integration
A good clamp design helps you in achieving fast and accurate movements. Lack of accuracy of the clamp can increase the mold time. When the mold opens for part removal. It’s critical for the applications of IML.

3. Speed
For thin wall manufacturing, speed is a more critical factor than pressure. The fast flow of plastic will be helpful for the proper and better filling of the part. High speed becomes a cause of high pressure. It proves helpful for reducing the pressure inside the mold.

4. Clamp Designing
How you apply clamp force to the mold is dependent on the degree of flexing. Good design has no more importance in