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yixun
Mold design and manufacturing process：
mold design:
yixunmold has in-house design department and with over 20 years experience in this field. we use UG/proe software. Our capabilities from single mold cavity to multi cavity ,hot runner to cold runner.we work closely with our customer to ensure the mold tool design efficiency and the smooth design process. We also have the 3D moldflow analysis to ensure the mold tool design accuracy and part quality.
Mold steel selection:
Selecting a tool steel grade is the first step to manufacture the medical mold . Although specialized tool steels aren’t required for medical injection molding, certain grades of steel are more appropriate for medical injection molding than others.
Working with a contract manufacturer to pinpoint steels will ensure that your mold tool will match your device’s design and help you avoid operating issues and tool damage. Steel selection will depend on your project’s specifications, including production volume, device design, plastic selection and surface finish.
The factors affect the medical mold steel selection :
there are several factors will affect the medical mold tool selection,including medical device design ,plastic material ,hardness ,surface finish ,strength and toughness.
The complexity of your device’s design will influence which steels will be incorporated into your tool. Complex designs require precise machining that certain grades cannot handle.
It is not unusual for tools with complicated geometries to have various steels incorporated into the design because there are dozens of options available for the core, cavity, inserts, polished surfaces and moving components.
For example, H-13 and S-7 pair well together for the cavity and core, respectively, in hardened steel molds. Abrasions and heat generation are reduced because the two steels don’t cause significant friction when rubbed together.
Plastic materials
Plastic material selection directly affects process parameters
and steel selection. For example, some plastics need to be run at higher temperatures (e.g., polysulfone) and will require hardened steels with high melting points.
Each plastic material has specific tolerances and characteristics that the tool steel needs to accommodate as well. Plastic materials that are abrasive or produce corrosive gases need steel tools that are tougher or more porous, respectively.
PVC is a notoriously corrosive plastic that must run in tools made with 420 stainless steel (see above). It’s used for tubing in medical devices and applications that require repeated actions.
Alternatively, if you are using a glass-filled material, then you will need a hardened steel to prevent wearing of the tool. Steels such as 420 stainless steel, H-13 and S-7 work well with glass-filled materials since they have good wear resistance and lower thermal conductivity (this allows parts to cool quickly).
Hardness
Steels are generally hardened to a certain Rockwell to increase the tool’s ability to accommodate higher production volumes or abrasive materials. Hardness is described as a material’s ability to resist indentation and abrasions. Indentation can be measured by the Rockwell or Brinell methods (the former is more common).
You have the option between pre-hardened and hardened steels.
Pre-hardened steels work well for larger or medium production volumes tools. Hardened steels have increased wear resistance and decreased long-term maintenance costs, making them ideal for high production volumes. Pre-hardened steels have quick turnaround times because you can cut your tool’s detail radiant to size and immediately commence with the manufacturing phase.
Hardened steels have slower turnaround times because the hardening process requires three steps: Cutting the detail of the mold close to size, heat treating the steel to a specified Rockwell and finally grinding / machining the steel to its geometry.
Surface finish
Medical devices that require a finer surface finish need to have a smooth, flawless appearance for their human interface. However, a finer surface finish is entirely dependent on the amount of abrasions in the tool because they will appear on the final part.Steels that can be hardened to higher Rockwells (e.g., H-13) have increased polishability, which result in minimal abrasions in the tool and subsequently fewer surface flaws on the final part.
Strength and toughness
Toughness is the ability of a steel to withstand sudden impact or shock; it can be measured with either an IZOD or Charpy impact test. Tougher steels work best for high production runs with abrasive materials.
mold making:
According to the designed mold drawings, use high-strength steel or aluminum alloy to manufacture the mold. The manufacturing accuracy and quality of the mold directly affect the accuracy and quality of the injection molded products.
Injection molding
Injection molding is an important part of the medical mold manufacturing process. The pretreated medical plastic raw materials are heated and melted, and then injected into the mold. Under high pressure, the plastic is filled into every corner of the mold, and after cooling, the required medical device accessories are formed.
Demolding and product post-processing
Demolding is to remove the product from the mold, and post-processing includes deburring, painting, assembly and other processes to make the product meet the final use requirements.
If you want inquiry ,pls contact us joyce@yixunmold.com
Mold design and manufacturing process：
mold design:
yixunmold has in-house design department and with over 20 years experience in this field. we use UG/proe software. Our capabilities from single mold cavity to multi cavity ,hot runner to cold runner.we work closely with our customer to ensure the mold tool design efficiency and the smooth design process. We also have the 3D moldflow analysis to ensure the mold tool design accuracy and part quality.
Mold steel selection:
Selecting a tool steel grade is the first step to manufacture the medical mold . Although specialized tool steels aren’t required for medical injection molding, certain grades of steel are more appropriate for medical injection molding than others.
Working with a contract manufacturer to pinpoint steels will ensure that your mold tool will match your device’s design and help you avoid operating issues and tool damage. Steel selection will depend on your project’s specifications, including production volume, device design, plastic selection and surface finish.
The factors affect the medical mold steel selection :
there are several factors will affect the medical mold tool selection,including medical device design ,plastic material ,hardness ,surface finish ,strength and toughness.
The complexity of your device’s design will influence which steels will be incorporated into your tool. Complex designs require precise machining that certain grades cannot handle.
It is not unusual for tools with complicated geometries to have various steels incorporated into the design because there are dozens of options available for the core, cavity, inserts, polished surfaces and moving components.
For example, H-13 and S-7 pair well together for the cavity and core, respectively, in hardened steel molds. Abrasions and heat generation are reduced because the two steels don’t cause significant friction when rubbed together.
Plastic materials
Plastic material selection directly affects process parameters
and steel selection. For example, some plastics need to be run at higher temperatures (e.g., polysulfone) and will require hardened steels with high melting points.
Each plastic material has specific tolerances and characteristics that the tool steel needs to accommodate as well. Plastic materials that are abrasive or produce corrosive gases need steel tools that are tougher or more porous, respectively.
PVC is a notoriously corrosive plastic that must run in tools made with 420 stainless steel (see above). It’s used for tubing in medical devices and applications that require repeated actions.
Alternatively, if you are using a glass-filled material, then you will need a hardened steel to prevent wearing of the tool. Steels such as 420 stainless steel, H-13 and S-7 work well with glass-filled materials since they have good wear resistance and lower thermal conductivity (this allows parts to cool quickly).
Hardness
Steels are generally hardened to a certain Rockwell to increase the tool’s ability to accommodate higher production volumes or abrasive materials. Hardness is described as a material’s ability to resist indentation and abrasions. Indentation can be measured by the Rockwell or Brinell methods (the former is more common).
You have the option between pre-hardened and hardened steels.
Pre-hardened steels work well for larger or medium production volumes tools. Hardened steels have increased wear resistance and decreased long-term maintenance costs, making them ideal for high production volumes. Pre-hardened steels have quick turnaround times because you can cut your tool’s detail radiant to size and immediately commence with the manufacturing phase.
Hardened steels have slower turnaround times because the hardening process requires three steps: Cutting the detail of the mold close to size, heat treating the steel to a specified Rockwell and finally grinding / machining the steel to its geometry.
Surface finish
Medical devices that require a finer surface finish need to have a smooth, flawless appearance for their human interface. However, a finer surface finish is entirely dependent on the amount of abrasions in the tool because they will appear on the final part.Steels that can be hardened to higher Rockwells (e.g., H-13) have increased polishability, which result in minimal abrasions in the tool and subsequently fewer surface flaws on the final part.
Strength and toughness
Toughness is the ability of a steel to withstand sudden impact or shock; it can be measured with either an IZOD or Charpy impact test. Tougher steels work best for high production runs with abrasive materials.
mold making:
According to the designed mold drawings, use high-strength steel or aluminum alloy to manufacture the mold. The manufacturing accuracy and quality of the mold directly affect the accuracy and quality of the injection molded products.
Injection molding
Injection molding is an important part of the medical mold manufacturing process. The pretreated medical plastic raw materials are heated and melted, and then injected into the mold. Under high pressure, the plastic is filled into every corner of the mold, and after cooling, the required medical device accessories are formed.
Demolding and product post-processing
Demolding is to remove the product from the mold, and post-processing includes deburring, painting, assembly and other processes to make the product meet the final use requirements.
If you want inquiry ,pls contact us joyce@yixunmold.com
