There are many rewarding aspects of producing industry-leading CNC routers and CNC plasmas, but none more rewarding than hearing success stories from ShopSabre customers around the country.

Among these great success stories is Olies Wood Shop in Los Angeles, who added a ShopSabre CNC router to their arsenal a few years back to ramp up their production and efficiency.

From hand-crafted beginnings

Olies Wood Shop is a furniture and dcor shop owned by the husband-and-wife duo of Art and Olie. Arts father moved to the U.S. from Honduras and started his own woodworking company decades ago, eventually helping Art start his own shop years later. At first, Art and his dad produced every part for every project by hand, which resulted in slow project timelines when creating furniture.

Because of this, they knew they needed a change once the business began to grow. They needed to find a way to be more efficient, and eventually started researching CNC machines.

Eventually, Art found ShopSabre, and began communicating with the team on possible equipment options.

For me it was a big investment, purchasing a CNC machine. After exchanging emails, I knew that ShopSabre was the company that I wanted to go with because the machines were very well-built and the price was very very reasonable for what you get.

Art also made note of the ShopSabre teams responsiveness in answering his many questions about CNC and the purchasing process.

Olie comes around

Despite Arts glowing first impression, Olie was not yet convinced. The couple spent a lot of time discussing the purchase and she came to understand how much a CNC router from ShopSabre would help the shops production. Art showed her the website and the benefits of CNC and just how much it would streamline many aspects of the business.

Eventually, Olie agreed, and now says purchasing a CNC router with ShopSabre was the best decision the shop has ever made.

This helps us produce so much more, Olie said. The machine is like five employees in one.

CNC changes the game

As Olies has grown, more and more orders have begun coming in orders theyd previously have been unable to fulfill without the help of CNC technology. Art and Olie are now able to cut an entire desk that would have previously taken five hours in just 15 minutes.

Because the machine automates so much of the production process, it also allows them to perform additional work around the shop and opens up new opportunities to create one-of-a-kind furniture while maximizing profitability.

The CNC software took a bit of education, which the ShopSabre team was able to assist in at every turn.

Obviously theres a learning curve, so its nice having that customer service anytime we needed help. Theyre very patient with us.

Even Arts dad whos been a woodworker for 40-plus years finds himself taking advantage of the CNC router in order to save time.

What would have taken him five hours takes the machine five minutes. We program it and everything, draw it up, and its done.

Art and Olies advice for first-time CNC buyers

From Arts experience in purchasing a CNC machine, his advice for first-time buyers is to opt for more options and functionality if you can afford it, as doing so is less expensive when paired with your initial purchase.

He and Olie also note that while CNC software can be intimidating to first-timers, it is much easier to work with than expected and is also supported by a wide range of tutorials and educational resources including ShopSabre customer service.

If we havent asked the question, someone else has. They know their stuff like the back of their hand. Theyll be on the phone and work with you. Theyre amazing at customer service.

The future of Olies

The addition of CNC technology to Olies shop has opened up new doors for them, especially in beginning to experiment with aluminum and other metals. Art and Olie are not metalworkers by trade, so ShopSabre has helped them learn the process in terms of setting feed speeds, working with different types of bits, and more.

Now theyre considering adding a ShopSabre CNC plasma to the shop to even further expand on their capability.

There are so many ideas we have for Olies as far as designs and different types of furniture that we want to build, and incorporating aluminum and steel, and its all possible because of the ShopSabre CNC machine.

Transform your shops capabilities with ShopSabre CNC

ShopSabre manufactures world-leading CNC routers and CNC plasmas to provide hobbyists and shop owners alike with unmatched precision, efficiency, and versatility. Whatever your goals may be, we are dedicated to helping you produce outstanding results at a fraction of the labor and cost.

OurIndustrial Series (IS)andPRO SeriesCNC routers provide industrial capability for a fraction of the price, while ourSideKick CNC plasmasdeliver professional quality at an entry-level cost.

Here are a few of the reasons ShopSabre is able to develop and produce such revolutionary CNC technology:

• Experienced in-house engineering talent
• The ability to totally fabricate and test designs onsite
• The ability to place the designs into production in-house

These are just a few of the advantages of being an American machine tool manufacturer. We offer commercial financing on our CNC equipment to help meet the needs of your budget.

Shop our unmatched collection of CNC routers and CNC plasmas in Minneapolis today to experience CNC the way it was meant to be.

Last time we talked about what goes into a perfect design. This time we look at some common everyday objects that could use a bit of redesign. All of the following have served their purposes admirably over the years, answering a felt need and in the process becoming ubiquitous in the modern world. But with advances in manufacturing technology and design capabilities we think they might stand for a bit of improvement, if there’s a clever designer or two out there who’s up to the challenge.

Rain falls on everyone. It’s a fact of life, and if it’s not rain then it’s too much sun. How to stay dry and in the comforting shade has been a common human concern for thousands of years, and so too the umbrella has been with us in one form or another since at least the time of the ancient Egyptian and Persian empires. Having gone through a series of technical and design innovations over the centuries, the modern version of the umbrella is familiar around the world: a central shaft around which is mounted a series of struts over which is strung a fabric cloth that, when deployed, sheds water and blocks the rays of the sun. Ideal, yes, and even somewhat elegant and sophisticated at times.

And yet who among us hasn’t struggled with the umbrella in a heavy wind, the parasol turning inside out and pulling us along the wet street like a drag chute? The struts break, water cascades down our backs or into the tops of our shoes. Umbrellas get tangled in doorways, drip water into the house, flap about like broken birds. If you’re on a crowded street during a shower, getting poked in the eye by the person next to you is a very real concern. And is there any sight sadder than this?

How many city streets are littered with umbrellas that have given up their last gasp? If there’s a better metaphor for the disposability of modern life, we don’t know it.

The design brief calls for a transparent, durable plastic shell for displaying a product on a store shelf, often some new electronic device. When the consumer buys the product, they take it home and then they are faced with the dreaded blister pack or clamshell that must be clawed through to get to the contents. And then the swearing starts, and then out comes a pair of scissors, knife, hacksaw or axe to get through the pack without destroying the thing you just bought. There’s actually a name for this phenomenon called “wrap rage”, and nothing has inspired it more than the blister pack and the sharp, pliable edges that tear into fingers and make a mockery of your shopping day. Some have attempted to solve this dilemma with innovative solutions such as this:

Is this the answer we’ve all been waiting for? Only time, and the fickle consumer, will tell.

While we’re on the subject of packaging – itself a lengthy topic – here’s one that may soon be disappearing from our lives, much to our general relief. The compact disc, or CD, started coming out into mass production in the early 80s, when digital music formats were beginning to sound the death knell to the beloved old vinyl LPs and stereo cassettes. CDs were indeed compact and promised us they would be durable, foolproof and keep providing pleasure year after year. Not so with the jewel case in which they were packaged. Although pristine when first opened, every jewel case cover ever made would soon snap off at the flimsy hinges.

The album cover art, printed onto cheap paper, would be wedged under four little plastic tabs. And then it would inevitably fall out, and putting it back was an exercise in monastic patience. And that little spindle in the center of the case, meant to hold the CD securely in place? The fingers snapped off, leaving the CD jostling around and getting scratched up, exactly what it was supposed to prevent. The jury is still out concerning what sounds best: vinyl LPs, CDs, or now lossless digital music files. But whatever history’s verdict, the jewel case was a design that never should have been.

Commercially successful typewriters were invented in 1868, and like umbrellas they’ve gone through many iterations over the years. By now, we’re all familiar with the so-called “qwerty” keyboard.

Legend has it, probably apocryphal, that the letters of the top row were arranged that way by an early and enterprising door-to-door salesman, who wanted to demonstrate how to spell the word “typewriter” on a single line. It’s more likely that the peculiar arrangement is due to the typewriter’s early use as a transcribing device for telegraph messages that were sent in code. Whatever the initial reason, looking at the keyboard objectively doesn’t reveal any good reason for why we continue to use it in this form today. It’s not the most ergonomically efficient array at all, and other competing designs, such as the Dvorak keyboard, have been attempted but all have failed to gain the public’s acceptance. So taken are we with this as the standard that we reproduce it on the touch screens of smart phones, which have no keys at all. This is simply a case where familiarity trumps function, and there’s no use fighting it.

There are other candidates on this short list. Possibly “hands-free” water faucets, which never seem to register the presence of a soapy, dirty hand desperately in need of washing. Who hasn’t waved their hands about underneath such a spigot, yearning for a proper handle? Maybe electrical multi-outlet strips, where one large plug always seems to block the space next to it, rendering the entire exercise moot. Other examples abound, and everyone has their favorite. These are important things to consider when designing your next prototype project. A design is never really finished. It can always be improved upon, simplified, streamlined. Another advantage to rapid prototyping and the flexibility it gives you to hone a product until it approaches the perfection of a mousetrap. Let us know what you think are the best and worst designed products out there.

The Future of Fashion: How Artificial Intelligence is Revolutionizing the Industry

The fashion industry has always been at the forefront of innovation, and the integration of Artificial Intelligence (AI) is no exception. AI is transforming the way fashion brands design, produce, and market their products, leading to more efficient processes and personalized experiences for consumers.

AI in Fashion Design

One of the most exciting applications of AI in fashion is in the design process. AI algorithms can analyze vast amounts of data, including current trends, historical sales data, and consumer preferences, to generate new design ideas. This not only speeds up the design process but also ensures that the designs are more likely to resonate with the target audience.

Virtual Prototyping and 3D Modeling

Another significant advancement is the use of AI in virtual prototyping and 3D modeling. Tools like those offered by Style3D allow designers to create and visualize garments in a virtual environment. This reduces the need for physical samples, saving both time and resources. Additionally, AI can simulate how fabrics will behave in real life, providing designers with valuable insights before production begins.

Personalized Shopping Experiences

AI is also enhancing the shopping experience for consumers. By analyzing browsing history, purchase behavior, and even social media activity, AI can recommend products that are tailored to individual preferences. This level of personalization not only improves customer satisfaction but also increases the likelihood of repeat purchases.

Supply Chain Optimization

AI is playing a crucial role in optimizing the fashion supply chain. Predictive analytics can forecast demand more accurately, allowing brands to manage inventory more efficiently. AI can also identify potential bottlenecks in the supply chain and suggest solutions, ensuring that products are delivered on time and at a lower cost.

Ethical and Sustainable Fashion

As consumers become more conscious of the environmental and ethical implications of their purchases, AI is helping brands meet these demands. AI can track the entire lifecycle of a product, from raw materials to the end consumer, ensuring transparency and sustainability. This not only helps brands build trust with their customers but also contributes to a more sustainable fashion industry.

The integration of Artificial Intelligence into the fashion industry is not just a trend; it’s a revolution. From design and production to marketing and sustainability, AI is reshaping every aspect of the industry. As technology continues to evolve, the possibilities for AI in fashion are limitless, promising a future that is more efficient, personalized, and sustainable.

Metal casting processes are the main supplier of blanks and parts for the machinery manufacturing industry. Every casting process in mechanical products accounted for a large proportion, such as internal combustion engine key parts (eight or nine) are castings, accounting for 70%-90% of the total mass, the quality of castings in the car accounted for 19%.

In the fast-changing world, casting is the most widely used metal processing technology. Knowledge about metal casting is important no matter what industry you are in.

What is metal casting

 The metal casting process refers to the molten metal liquid poured into the molds for metal casting, when the metal liquid cools and solidifies to obtain the blank or parts of the process called the metal casting process.

The history of the metal casting process is very long, which means that this metal casting process has been tested over a long period of time and has been quite perfect and mature, and many metal casting products in our life are manufactured using this process. For example engine blocks for cars, lamp posts, wind turbines, bicycle pedals, etc. Let’s learn more about the metal casting process.

metal casting process

Designing a pattern and making a metal casting mold

You need to first design a pattern to determine the shape of the mold, such as a 3D printing model or CNC prototype of the object. The mold can be made of wax, plastic, sand, or even wood, and it needs to take into account the shrinkage that occurs when the metal cools, as well as the workability of the structure of the part based on precise calculations. Finally, gates are placed at the appropriate locations in the mold to allow the molten metal to flow evenly and smoothly into the mold.

Selection of metal materials

The main alloys often used in casting are aluminum, solid metal, sheet metal, copper, and in the case of precious metals commonly used in the jewelry industry are gold, silver, copper, and platinum. These metals are mechanically capable of meeting the requirements of metal cast parts, they are a mixture of several elements, strong and durable.

Melting metal material

The metal is casting molding process is like, playing at the beach and leaving footprints on the sand by yourself, which can be simply understood as your feet are the model and the footprints are the mold of your feet.

The molding process is a multi-step process, this process will use the metal casting sand, the sand, and the model into the sandbox, tightly press the sandbox, so that the sand and the model closely fit, the purpose is in the sand around the model to form the geometry of the casting, the model is removed, the geometric features of the model is perfectly copied, the mold is thus created. If a reusable mold is needed, a durable and indestructible metal mold can be made.

Pouring into the mold

Pouring or injecting the heated molten metal into the mold. For example, in gravity casting, the molten material can be poured directly into the mold downward by gravity; however, in high-pressure die metal casting, the molten material can only passively enter the mold under high pressure, and in addition, high closing forces are required to keep the mold secure.

Removing the mold

The most troublesome part of this process is the separation of the sand from the complete and clean casting, a process we generally call sand removal. The mold is vibrated to shake off the metal casting sand that is clinging to the casting.

The shaken sand is then collected and cooled for recycling. The surface of the casting should not be covered with too much sand, which will cause defects on the surface of the casting and is not conducive to making full use of the sand.

Some companies with good conditions also use sand conditioners to remove and cool the sand, as well as evaporate water vapor to speed up the process of separating the sand from the casting. Some metals need to be quenched in water after solidification because water will help remove mold. For reusable molds for metal, castings are removed by automated ejector pins, so some ejector pin marks will be left on the back of the casting.

Completion of metal casting

The metal casting project in the final step is trimmed and cleaned. During the trimming process, all molding material is removed from the object, and the metal casting is ground and polished, for example, by cleaning in water to remove residual mold material, removing casting gate marks, and rough protruding edges.

Different types of metal casting

Sand casting

The sand casting method is very common and relatively simple because the metal casting sand is particularly cheap, it can also withstand the heat, the process is completed, it is easier to remove the surface of the sand, but the surface of the sand casting is usually very rough. It is difficult to achieve high accuracy in dimensional tolerances.

Sand casting is more suitable for the production of large and simple parts, such as roadside fences, iron pots commonly used at home, or car engine parts. So, sand casting is very helpful in different aspects.

Investment casting (lost wax casting)

Investment casting is also known as lost wax casting and is used to draft every type of wax pattern. Moreover, this method is to cover and wrap the outside of the model made of wax with refractory material, then heat the model and let the wax flow out so that you can get a molded shell with the same high-temperature resistant material as the wax mold, then the molten metal is injected into the mold, and after the solution cools, the metal model is finished.

Disappearing mold casting

The disappearing mold casting is in accordance with the requirements of the process, the first production bubble model, and then in the model’s surface coated with special high-temperature resistant paint, dry in the sandbox, according to the process requirements filled with dry sand, the use of three-dimensional vibration tightening, extraction of air to the vacuum state casting metal liquid, at this time the model vaporization disappeared, the metal liquid replacement model, reproduce the bubble model of the same casting.

Centrifugal casting

Centrifugal casting is the technology and method of injecting a metal solution into a high-speed rotating mold, and the molten metal is covered with the whole mold under the action of strong centrifugal force, and waiting for the metal solution to cool down to form the casting. Because the effect of centrifugal force is very strong, the inclusions and gases inside the mold are easily discharged, and the cooling is generally from the outside to the inside, the casting is very fine in an organization and the mechanical properties are close to the forging process.

Die metal casting

The die metal casting is more like plastic injection molding. First, two metal steel molds need to be prepared as cavities for the molten metal, and then the molten metal is pressed into the cavities under high pressure, and then the fine arts can be manufactured. Die metal castings generally have an excellent surface finish, but the cost of custom cavities is higher, so this process is more suitable for high volume production because the metal cavities can be used multiple times.

Gravity casting

Gravity casting predates other metal casting processes, it is a reusable metal mold casting metal method also known as casting. As the name implies, gravity casting relies on gravity to turn the metal solution from top to bottom to cover and fill the mold, rather than relying on pressure. This mold must be heated prior to casting and the material is usually made of iron, which has low thermal fatigue.

Other types of metal casting

There are some other metal castings including die casting, lost wax casting, slush casting, hollow castings, vacuum casting, continuous casting finished casting, and iron casting. Moreover, all these casting processes are applicable to the same metal and also on raw material.

Pros and Cons of metal casting

A combination of the above characteristics of various casting processes, metal casting can be concluded that the following pros and cons.

Pros

1. It can produce the arbitrarily complex shapes of the parts, especially the internal cavity shape complex parts.

2. It is Very adaptable, the metal material is not limited, the size of the casting is almost unlimited.

3. Wide source of manufacturing materials, high recovery rate, low investment in equipment.

4. Excellent bearing quality, suitable for mass production, and can produce thick-walled parts.

Cons

1. The production procedure of casting is more complicated and difficult to control. The surface finish may produce defects such as porosity, shrinkage, slag holes, cracks, poor fusion, sand holes, etc.

2. The dimensions of the castings deviate, and the dimensions are not as accurate as CNC machining.

3. For casting workers, the casting equipment is more dangerous， the working environment is poor, high temperature, dust, and labor intensity.

The application of Metal Casting

Power station equipment

Power station equipment is a high-tech product, the reliability of the parts has very strict requirements because the parts need to operate continuously for a long time under high load, thermal power stations and nuclear power station equipment in many parts also need to withstand high temperature and high-pressure steam corrosion. Cast steel parts can meet these requirements to the maximum extent possible, widely used in power station equipment.

Railway locomotives and vehicles

Railroad safety is of paramount importance, so some key components of locomotives and vehicles, such as wheels, side frames, shaking pillows, hooks, etc., are the traditional cast steel parts.

Construction, construction machinery, and other vehicles

Most parts of construction machinery and engineering machinery are subjected to high loads or need to withstand impact wear, a large part of which are metal casting parts, such as the active wheel in the action system, load-bearing wheel, rocker arm, track plate, etc. General automobiles rarely use cast steel parts, but special off-road vehicles and heavy trucks also use a lot of cast steel parts in the action part.

Conclusion

A different metal casting method in the manufacturing industry has a wide range of uses, especially in construction and transportation, but also it is a very inexpensive method, its history is also very long, after the test of history, metal casting services are increasingly available to meet the different production requirements.

So, metal casting, permanent mold casting, plaster mold, casting metals, shell mold, and all other casting processes help the manufacturing industry to increase productivity at a good level. The metal casting process explained their capability by giving different shapes, and metal objects.

3D printed molds for injection molding are becoming increasingly popular in the manufacturing industry. It is a great addition to the injection molding process portfolio and offers a competitive alternative to traditional injection mold materials.

In this article, we will dive into what a 3D printed injection mold is and its types, benefits, and limitations. In the end, we also share some helpful tips and tricks for mold designers and engineers. Let’s begin!

Contents
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I
What is an Injection Mold?

II
3D Printing Mold vs. Aluminum Mold

III
Benefits of 3D Printed Injection Molds

IV
Limitations of 3D Printed Injection Molds

V
Tips & Tricks for 3D Printed Injection Molds

VI
3D Printing Methods and Materials to Manufacture Molds

VII
Conclusion

VIII
FAQs

What is an Injection Mold?

Injection molds are arguably the most important component in injection molding setups. The mold is a multi-part assembly with a cavity inside it that is an exact replica of the product’s final geometry.

An injection system pumps molten raw material into this cavity, where it cools down to take its final form. Afterward, an injection mechanism, which is also inside the mold, then ejects the final part. Hence, the injection mold serves the primary purpose of giving the part its shape and also ejecting it.

There are numerous properties that a high-quality injection mold must possess. It must have good thermal stability to minimize thermal expansion, high strength to bear the clamping pressures, and good wear resistance for durability.

3D Printing Mold vs. Aluminum Mold

Conventionally, aluminum has been the standard material choice for manufacturing low-to-medium volume production injection molds. However, 3D printed molds for injection molding are rapidly gaining traction owing to numerous benefits like cost-saving and design flexibility.

The main difference between a 3D printed mold and an aluminum mold is how they are made. The primary manufacturing process for aluminum molds is CNC machining. 3D printed molds, on the other hand, are made from 3D printing, of course.

It may seem like a trivial difference but it is, in fact, quite significant and calls for a discussion on 3D printing mold vs. aluminum mold.

However, first, let’s go over the two main types of 3D printed injection molds.

Metal Frame Reinforced Mold

This type of injection mold borrows elements from both aluminum molds and 3D printed molds. The basic internal structure including the cavity and channels is 3D printed. This 3D print is then fit inside an aluminum structure for better stability and durability.

The aluminum frame reinforcement allows for higher molding pressures and prolongs the mold’s life. Engineers can also easily replace the 3D printed mold components in case of design changes or wear and tear.

Standalone Molds

Standalone molds are made entirely by 3D printing. As 3D printing is getting more robust very quickly, standalone 3D printing mold is gaining popularity in the injection molding industry.

A major advantage of standalone molds is that engineers get additional design flexibility for features like injection channels, gates, etc.

Benefits of 3D Printed Injection Molds

3D printed molds for injection molding enjoy numerous benefits over their metallic counterparts. We will highlight some of the main advantages of using a 3D printed mold.

Cost-Effective

It is no secret that cost management is a big part of efficient manufacturing. A 3D printed mold is significantly cheaper than metal molds.

CNC machine tools are oftentimes expensive and require costly maintenance. 3D printers, on the other hand, are cheaper machines and easy to maintain. The cost of 3D printing raw materials is also lower than injection molding metals.

Labor costs also differ for both methods. CNC machines are complex equipment and require a qualified machinist to operate them. 3D printers, although not a walk in the park, are still more accessible to a wider group of technicians.

Time-Saving

Another important aspect of high manufacturing productivity is time management. A major advantage of using a 3D printed mold vs. aluminum mold is the remarkable time saving during the mold making process.

CNC machining is a time-intensive process, sometimes taking up to a week to fully manufacture a complicated injection mold. The 3D printing process is much quicker and has fewer steps than machining. The average mold-making time is in the order of a few hours, giving 3D printed molds an obvious edge.

Design Flexibility

3D printing is known for its rapid prototyping capability. It is quick, cheap, and allows engineers to test various design iterations.

The same logic extends to 3D printing molds for injection molding. Mold designers can quickly eradicate any mistake or kinks in the mold design. Moreover, it is also very convenient to incorporate product improvements into the manufacturing line – all it takes is a simple reprint.

This kind of design freedom is not affordable with CNC machining, where even a single production is heavy on the budget.

Suitable for Low Volume Injection Molding

3D printed molds are well-suited to low-volume production initiatives. As we will discuss shortly, although they possess remarkable mechanical properties, they tend to wear more quickly than their metallic counterparts over time.

This makes them ideal for production runs where a small-to-medium number of parts are manufactured. In such setups, investing in an expensive metal mold is inefficient as the mold remains under-utilized at the end of the production run.

Moreover, low-volume production, on average, is more about product development and testing. The design can change midway through production if an update is required or a mistake is found. In this scenario, a 3D printing mold is ideal as updating is both cost-effective and time-saving.

Limitations of 3D Printed Injection Molds

Pros and cons go hand in hand. Therefore, this discussion will be incomplete if we ignore the drawbacks of a 3D printing injection mold.

Low Structural Integrity

3D printing is progressing very fast but it still lags behind conventional manufacturing processes like CNC machining in some aspects. It has several inherent quality issues like porosity and lack of bonding that decrease the structural integrity of 3D printed molds for injection molding.

Generally, a 3D printed mold has lower strength, hardness, and wear resistance (hence, the need for aluminum reinforcements). They tend to fail under extreme temperatures and pressures, which are sometimes necessary to achieve high-quality injection molding products.

As a result, in some cases, 3D printed molds are not a suitable substitute for cast/forged aluminum molds.

Surface Wear

3D printed molds for injection molding are not as wear-resistant as metal molds. Their surface quality deteriorates quicker than aluminum under the high temperatures and pressures of injection molding. This translates to the product’s surface as well.

In addition to this, 3D printing molds is a layer-by-layer manufacturing process. Due to this, 3D printed injection molds have a wavy surface pattern (also known as the stair-stepping effect) that increases the surface roughness of injection molding parts.

A common solution is to use surface finishing methods like filing, grinding, or chemical treatment to improve the mold’s surface quality. However, it is a challenge to perform these operations on a small mold with complex geometry, which is quite often the case with 3D printed molds.

Long Production Cycle

The cooling time comprises a big chunk of the injection molding production cycle. Since metals generally have higher thermal conductivity than the plastic materials used for 3D printed molds, it takes longer for the molten raw material to solidify when inside a 3D printed mold vs. aluminum mold.

Owing to this, we advise mold engineers to calculate the expected cooling time for their injection mold designs before deciding on the manufacturing process.

Shrinkage and Warping

Shrinkage and warping are two common 3D printing defects affecting the quality of a 3D printed injection mold. Plastics are very sensitive to heat and are prone to deforming (warping) during injection molding.

As the mold itself deforms, the shape of its cavity changes, affecting the final dimensions of the part.

In most cases, mold designers are able to mitigate this issue by incorporating appropriate shrinkage allowances in their molds. However, in the case of 3D printed molds, these allowances are hard to predict due to the non-uniform behavior of 3D printed structures.

Tips & Tricks for 3D Printed Injection Molds

We hope the above information on 3D printed injection molds for injection molding has added to your knowledge on the subject.

In this section, we will share some useful tips and tricks from our design experts that will help you improve your mold designing skills.

Improve Thermal Conductivity with Composition Materials

High thermal conductivity improves cooling time in injection molding. Several conductivity-boosting additives are available in the market like graphene, boron nitride, metallic fillers (copper powder, aluminum flakes), etc.

Surface Coating

Poor wear resistance is a major drawback of 3D printing molds. Appropriate surface coatings like metal or ceramics are quite useful in enhancing the surface properties of 3D printed injection molds.

Avoid Support Structures on Critical Internal Faces

Most 3D printing techniques use support structures to uphold the part during printing. They leave a mark on the part after the finishing technician removes them. Take care not to have any of these support structures on faces that form the cavity of the mold as their leftover marks will appear on the part as well.

Decrease Layer Thickness and Printing Speed for Better Surface Finish

The surface finish of a 3D printed mold depends on the layer thickness and printing speed parameters of the 3D printer. Keep these settings low to get a finer 3d printing surface finish.

Draft Angles are Slightly Higher than Aluminum Molds

3D printed structures require higher draft angles in the mold owing to their different material properties. Experts suggest including an average draft angle of 3° for the vertical faces of the injection mold.

Ventilation is Key

Air pockets tend to develop inside mold cavities and decrease surface quality. It is good to have shallow air vents slightly below the cavity surface to avoid this problem.

3D Printing Methods and Materials to Manufacture Molds

In this last section, We briefly introduce some 3D printing techniques and materials suitable for 3D printing mold.

Common 3D Printing Methods

• Stereolithography (SLA)
• Fused Deposition Modeling (FDM)
• Material Jetting
• Selective Laser Sintering (SLS)

Common 3D Printing Materials

• ABS (Acrylonitrile Butadiene Styrene)
• PETG (Polyethylene Terephthalate)
• PP (Polypropylene)
• Nylon
• Thermoplastic Elastomers (TPE)

Conclusion

This concludes our discussion on the interesting topic of 3D printed molds for injection molding. 3D printed molds are an emerging alternative to aluminum molds that offer benefits like cost- and time-saving, and design flexibility, and are great for low-volume production.

Some of their cons include low structural integrity and wear resistance when compared with metal molds, but there are specialized solutions to eradicate these issues.

Are you looking for a fast mold maker for your injection molding project? WayKen offers rapid tooling and injection molding services with strict quality control. Our advanced tooling mold and 3d printing technologies provide unparalleled accuracy and cost-effectiveness in product construction. Just contact us today, and you will get a quote and design for manufacturing analysis.

FAQs

How expensive are 3D printed molds vs. metal molds?

3D printing molds are relatively inexpensive compared to metal molds. Typically, a 3D printing mold costs under $200. A metallic mold is easily $5,000+. For a low volume setup, 3D printed molds are a clear choice.

Which common 3D printing is best for injection molds?

Comparing only FDM, SLS, and SLA, we suggest using SLA for producing injection molds. SLA products are robust, smooth, and precise. FDM molds face demolding issue and are not as smooth as SLA molds. Similar issues are commonly reported for SLS products.

How to improve the cooling time of a 3D printed injection mold?

3D printed molds do not cool down as quickly as metal molds due to their low thermal conductivity. A good tip is to use compressed air to increase convective heat transfer or you may use interchangeable stacks.

Nov 04/20

5 Factors to Consider When Choosing an Automotive Supplier

The Coronavirus pandemic took a temporary toll on the automotive industry. In fact, global sales are expected to decline by roughly 14% in 2020.

While 2020 was a tough year, there is optimism for 2021. The government-mandated lockdowns have created pent up demand in the automobile industry. Buoyed by low-interest rates, experts believe that profits for global automotive OEMs will increase by 50%.

This means that vehicle manufacturers will be ramping up production in 2020. Read on to learn how to select the right automotive supplier. Explore five factors to consider when choosing a supplier for your parts needs.

1. Delivery Schedule

Can the supplier meet your schedule requirements? Strong demand for new cars, especially for manufacturers like Tesla, is anticipated as we move into 2021.

This is going to present a challenge for suppliers without the capability to ramp up parts production. The best suppliers are using techniques like rapid prototyping to meet accelerated delivery needs.

Before signing a contract, you should verify that the supplier can meet your schedule requirement. Ideally, you should receive this information when obtaining a price quote. The supplier should indicate how many days after receipt of the order for the ordered parts.

2. Quality

The top vehicle manufacturers demand high quality. They cannot sacrifice their brand or reputation for a poorly produced product.

Your search for a supplier should verify that they have the proper certifications and quality control procedures. For example, Mayco is IATF-16949 certified. This certification is for the manufacture and assembly of plastic injection molded, thermoformed, and painted interior and exterior trim products.

Vehicle manufacturers can feel confident buying interior and exterior trim products thanks to this certification. It means they are following robust quality assurance and inspection process prior to delivery.

3. Price

Any company that says that price is not a factor is being dishonest. Every top auto manufacturer is looking to cut their bottom line.

While quality must not be sacrificed, manufacturers are also looking for competitive pricing. With the learning curve and high economies of scale, large suppliers can reduce the price of parts without sacrificing quality.

4. Covid-19 Preparedness

Unfortunately, the world needs to learn to live with Covid-19. Suppliers need to be prepared to prevent and mitigate the spread of the coronavirus.

Vehicle manufacturers cannot afford to lose parts distribution because of a community spread at a supplier. The supplier should have sanitation processes in place to prevent the spread of the virus.

In addition, they should have policies in place to quarantine employees who are Covid-19 positive. Lastly, they should utilize contact tracing to minimize the impact on the workforce.

5. Environmentally Conscious

Lastly, suppliers should be committed to protecting the environment. Suppliers like Mayco are responsible for recycling millions of pounds of plastic.

There should also be an emphasis on climate change. The best suppliers are actively working to reduce their carbon footprint.

A Recap of Choosing the Right Automotive Supplier

You can find great parts suppliers by focusing on the right elements. Factors like meeting delivery schedules and reviewing quality certifications are certain to help.

If you are still looking for the right automotive supplier, contact us today to speak with a professional.

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