HOW TO MAKE ALUMINUM MOLDS

 With the rapid development of the manufacturing industry, the aluminum alloy die-casting industry has also obtained many development opportunities, especially the aluminum alloy die-casting castings have been widely used. So what are the manufacturing processes of Aluminum molds? What other matters need attention? Let’s find out together

What is a Die Cast Aluminum Mold?

Die Cast Aluminum Molds is also commonly known as Dies. These molds are used for the mass-production of aluminum parts. Mold making used to be a difficult task before. Thanks to the CNC Machining technology mold making is now faster and more efficient than ever.

Aluminum Die casting Mould requires a material that has higher strength and melting temperature than Aluminum. Otherwise, the die will be damaged during the casting process. Usually, steel molds are used for aluminum die casting.

High-quality steel is quite costly and hard to machine. So, the die tooling cost is relatively high. Even though the high tooling cost, aluminum die casting toolings provides the best economy and quality for large volume production.

How To Make Aluminum Molds

Aluminum mold design: divided into product distribution, runner design, slider, thimble, exhaust, slag design, etc. This requires the mold designer to have sufficient professional experience and familiarity with the product, so that the designed aluminum alloy die-casting mold can have a positive impact on the service life and die-casting products

Aluminum mold design drawing: draw all the parts and accessories of the aluminum alloy die-casting mold one by one, first draw the three-dimensional drawing, and then draw the two-dimensional drawing. After the drawing is completed, the design is checked first, and then the supervisor of the mold department, the corresponding engineer of the project and the company check the drawing to ensure the smooth production of aluminum alloy die-casting molds

Aluminum mold processing: mold processing is divided into mold base processing, mold core (mold core) processing, thimble, slider and other accessories processing. In addition, it is also necessary to use mold manufacturing equipment such as electric discharge machine, milling machine, grinding machine, numerical control, heat treatment, etc.

Assembling the aluminum mold: This section requires the smooth completion of the previous process and the completion of various accessories, usually completed by the assembler responsible for the set of molds. This assumes that the assembler is very familiar with such molds, has some experience, and has a good understanding of drawings, assembly techniques and various mold making machines. Otherwise, assemblers cannot handle it independently during assembly, and experienced assemblers can often assemble a set of molds independently in the face of various problems

Aluminum mold real mold: After the mold assembly is completed, the corresponding die-casting machine should be set up to match the production and actual mold progress, and the mold should be tested for T1. Here, the person in charge of the die-casting department and the assemblers, engineers and business personnel in charge of the mold group should help to complete, and the quality inspection should be carried out after the sample is cooled.

Product inspection after aluminum mold trial: This process must be carried out jointly by quality personnel, engineers and the company. If the precision, appearance, and structure of the product conform to the design parameters of the mold and are considered qualified, the clerk can send it to the customer for inspection and acceptance. If not, it is necessary for the mold designer, mold manager and fitter to discuss improvements and solutions together until the product is qualified

Advantages of  Aluminum Die Cast Mold

Aluminum die cast mould has made the production of aluminum parts a lot easier. Some of the benefits of die casting molds are explained below.

• A single mold can produce thousands of parts
• Can produce parts with very tight tolerances
• Can withstand high temperatures
• Can withstand very high pressure
• Significantly reduces production cost for large volume production
• Can manufacture multiple aluminum parts at one go
• Increased rate of cooling and solidification allows faster production

For these multiple advantages, aluminum die-cast mold is being used for boosting aluminum die casting capacity.

Single vs. Multi-Cavity: A Comprehensive Guide to Injection Molding

Injection molding has revolutionized the plastics industry by allowing companies to quickly, efficiently and cost-effectively produce large quantities of the same part. This is the method of choice compared to other manufacturing methods such as CNC machining, die casting and polyurethane casting. This comprehensive guide provides a detailed analysis of single-cavity and multi-cavity molds and explains their differences, advantages and disadvantages to help you make an informed decision on which type to use in your application.

                                                             Multi cavity mold

Introduction to Injection Molding

Injection molding is a manufacturing process used to produce high-volume plastic parts. It involves injecting molten plastic into a mold cavity, which then cools and solidifies to form the desired part. The process is efficient and can produce complex parts with tight tolerances. Injection molding is used in a wide variety of industries, from aerospace and medical devices to consumer goods and toys.

Understanding Mold Cavities

A mold cavity is a cavity within a mold into which plastic is injected to form the desired part. The number of cavities in a mold can significantly affect the production time, cost and efficiency of the injection molding process. There are two main types of mold cavities: single-cavity and multi-cavity.

single cavity mold

Single-cavity molds consist of a cavity into which plastic resin can be injected, producing one product per cycle. This type of mold is usually recommended for the production of small batches of plastic products.

Advantages of the single chamber format

11. Reduce mold manufacturing costs: Compared with multi-cavity molds, the design and manufacturing costs of single-cavity molds are lower.

12. Ease of design and manufacture: Single-cavity molds are easier to design and manufacture, allowing for better quality control and shorter delivery times.

13. Improved control of the molding process: By monitoring only one cavity, injection molding machine operators and mold makers can better manage the molding process, resulting in improved part quality.

Disadvantages of the single-chamber format

14. Low productivity: Since only one part is manufactured per injection cycle, single-cavity molds have lower productivity compared to multi-cavity molds.

15. Higher unit manufacturing cost: Since fewer parts are produced in each cycle, the unit cost of a single cavity mold is higher.

Shapes with multiple cavities

Multi-cavity molds consist of multiple cavities, allowing manufacturers to produce multiple parts in one cycle. This type of mold is ideal for producing large numbers of identical parts quickly and efficiently.

Advantages of Multi-Cavity Shapes

16. Higher productivity: Multi-cavity molds can produce multiple parts per cycle, greatly increasing productivity and reducing production time.

17. Reduced part manufacturing costs: Since more parts are manufactured per cycle, multi-cavity molds have lower unit costs, making them more cost-effective for mass production.

18. Improve efficiency: By using multiple mold cavities, manufacturers can better utilize the cycle time of the injection molding machine, further improving production efficiency.

What is a Die Cast Aluminum Mold?

 Manufacturing method of aluminum mold

Die Cast Aluminum Molds is also commonly known as Dies. These molds are used for the mass-production of aluminum parts. Mold making used to be a difficult task before. Thanks to the CNC Machining technology mold making is now faster and more efficient than ever.

Aluminum Die casting Mould requires a material that has higher strength and melting temperature than Aluminum. Otherwise, the die will be damaged during the casting process. Usually, steel molds are used for aluminum die casting.

High-quality steel is quite costly and hard to machine. So, the die tooling cost is relatively high. Even though the high tooling cost, aluminum die casting toolings provides the best economy and quality for large volume production.

Aluminum mold design: divided into product distribution, runner design, slider, thimble, exhaust, slag design, etc. This requires mold designers to have sufficient professional experience and product familiarity, so that the designed aluminum alloy die-casting molds can have a positive impact on service life and die-casting products

Aluminum mold design drawing: Draw all the parts and accessories of the aluminum alloy die-casting mold one by one, first draw the three-dimensional drawing, and then draw the two-dimensional drawing. After the drawing is completed, the design inspection will be carried out first, and then the drawing inspection will be carried out by the supervisor of the mold department, the corresponding engineer of the project and the company to ensure the smooth production of aluminum alloy die-casting molds

Aluminum mold processing: mold processing is divided into mold base processing, mold core (mold core) processing, thimble, slider and other accessories processing. In addition, mold making equipment such as EDM machines, milling machines, grinding machines, numerical control, and heat treatment are also required

Assembling the aluminum mold: This part needs to successfully complete the previous process and the completion of various accessories, and is usually completed by the assembler who is responsible for this set of molds. This is assuming that the assembler is familiar with such molds, has certain experience, and has a good understanding of drawings, assembly techniques, and various mold making machines. Otherwise, the assembler cannot handle it independently during assembly, and an experienced assembler can often assemble a set of molds independently when faced with various problems

Aluminum mold real mold: After the mold assembly is completed, the corresponding die-casting machine should be set up to cooperate with the production and actual mold progress, and T1 mold test should be carried out on the mold. Here, it is completed with the assistance of the person in charge of the die-casting department, the assembler, engineer, and salesman in charge of the mold group, and the quality inspection is carried out after the sample is cooled.

Product inspection after aluminum mold test: This process must be jointly carried out by quality personnel, engineers and the company. If the precision, appearance and structure of the product meet the design parameters of the mold, it is considered qualified, and the clerk can send it to the customer for acceptance. If not, the mold designer, mold department manager and fitter are required to discuss improvement and solutions together until the product is qualified