Die casting mold making

Aluminum die casting is a process in which hot, liquid metal is injected into steel molds. These molds are known as dies. Aluminum is a desirable alloy to use for die casting because it creates lightweight, corrosion-resistant materials that can operate in very high temperatures. These die castings are used to produce parts for cars, airplanes, pumps, light fixtures and power tools.

Die Casting Tooling
•Dies are made of two sections: The fixed die half, also known as the cover half, and the ejector die half which is movable in order for the castings to be taken out. The sides of the die fold together and close like a book and are securely kept together by locking pins. Ejector pins are used to help remove the casted part. Located on the inner side of the two folding sections are negative reliefs of the metal part that is going to be made. On the cover half there are open holes called sprue holes and this is where the molted metal is poured into the die until it fills all of the nooks and crannies of the cavity on the inside of the mold. The ejector half contains passageways called runners and inlets called gates. These depressions in the die route the molten metal and force it to move into the hollow cavity of the mold. There are also openings in the dies for coolant and lubricants to be added. Lubricants are necessary as they allow the cooled product to be easily removed.
Die Casting Machinery
•These machines hold the two die halves together under intense hydraulic pressure. The place where the two fixed halves meet the ejector is called the die parting line. The projected surface area of the part that is being cast is measured at this line, and that number is used to determine how much hydraulic pressure is needed to inject the metal into the die cavity. There are two kinds of die casting machines: hot chamber and cold chamber. Hot chamber machines are used when the dies are made out of lead, magnesium, copper or zinc. These metals and other low melting-point alloys are used to made metal pots and other things that can chemically interact with other metals and be corroded easily. Cold chamber machines are used for aluminum dies and have a metal sleeve into which molten metal is poured. This can be done manually or by a computer-automated system. A hydraulic plunger pushes into the sleeve and forces the metal into the aluminum die at a very high pressure to ensure that the cavity is filled.
How Dies Are Made
•Dies for aluminum casting are made by creating a model of the part to be manufactured and then enveloping it with aluminum and allowing it to cool. When the aluminum is removed, it contains the cavity where the product will be formed. Dies can be made via squeeze casting, where a molten metal alloy is created at a very high pressure to make dense, high-quality, heat-treatable components. Semi-solid molding uses semi-solid billets to make a die that is heat treatable and has a low porosity. The surface of the pieces made will it have a smooth, clean-looking appearance.
Types of Dies
•Single-cavity dies produce a single component. Multiple-cavity dies produce a number of identical parts and may look like branches of a tree, with the trunk forming the separation point. A unit die is used when several different parts need to be made for a particular assembly; a master lock for the front door of a house, for example.

Now we have very matured moulding technologies for the two colors or even four colors injection moulding, normally there are two types of solutions.
1. the 2nd injection realized by the machines’ clamping plate rotory.
2. the 2nd injection moulding realized by the moulds actions.

This two different types of multi-colors injection molding have themselves adavantages.
And the injection moulding machine’s injection system can be both horizonal or vertical.
Dakumar produce this two type of multi-colors injection moulding machines.

Plastic materials and products also play a vital part in cutting-edge technologies. For example, plastics are used in various places throughout the space program, Medical Equipment, Industry;Farm;Household appliance;and Military fields,They played an important role in our Daily life. It is obvious that plastic has literally become the cornerstone of our society. With so many of our everyday products being made of plastic, it is easy to understand why the plastic injection molding industry is so important to various businesses and consumers.

If your company or business relies on plastic products or parts that require custom moldings and is looking for something that will give you the cutting-edge over your competitors, consider plastic injection molding. A large amount of all plastic products and materials are produced using this process, and more specifically the process of custom injection molding.

Does Plastic Injection Molding Measure Up?As with any process, there are both advantages and disadvantages associated with plastic injection molding. However, the number of advantages far outweighs the number of disadvantages for almost all companies that are considering injection molding. The advantages include being able to keep the production rapid and efficient, being able to replicate a large number of the products being produced, and being able to lower the labor costs. The decrease in cost stems from the machinery that handles and completes a majority of the work and the precision of the process that lowers the scrap costs because of plastic injection molding accuracy.

On the other hand, there are some disadvantages that affect smaller companies. When these companies want to use plastic injection molding as a means to produce parts, the equipment needed to accomplish the task is expensive and causes the operating costs to skyrocket. In these kinds of situations, the financial burden may outweigh the benefits of using plastic injection molding. However, there are businesses that specialize in custom plastic injection molding. They will be able to create the mold with complete exactness. The customer is given the mold along with an estimated cost for the entire job.

Plastic Injection Molding offers Answers.So why is it that plastic injection molding has become so widely used by companies? The answer is simply that it can provide the products your business needs to prosper and the products your customers need and want. With its unique ability to be produced in almost any shape or form, plastic can meet all of the very specific needs of customers. If a product is made of plastic, there’s a reason. And chances are the reason has everything to do with helping your customers get what they want: Safety. Performance. Value. Plastic injection moldings will help make these things possible.
For more information regarding to Plastic injection molding or injection molds please go to our

It’s extremely advised which you make use of the interactive injection mold design tutorial to train you about mold design. It could be self-paced and total of illustrations, animations and just about each and every point you have to get started. Current CAD/CAM application is incredible in its capability to figure out and highlight locations of concern in injection mold design. Undercuts and associated parting line troubles are produced extremely apparent two dimensionally on individual personal computer monitors-allowing to remain aside from pricey and time-consuming mistakes. Luckily, the Injection Mold Design created is usually a complicated piece of tooling, because it need to include numerous needed features.

Nonetheless, it’s even now important that the injection mold design should be in accordance towards the dimension within the product that you will be processing. An appropriate thickness inside the design may also determine the items cooling cycle. Professional might supply forensic expert observe testimony, litigation consulting providers, forensic investigation, and forensic testing if suitable in litigation locations as getting a Plastic material substance Injection Mold Design Expert Observe and Troubleshooting Professional Observe. Intota provides attorneys and legal experts the opportunity to query an professional original screening inquiries and query the authorities companies particulars by submitting an specialist request. The wall about the injection mold design should to become thick sufficient in purchase for that product to possess a superb exterior produce, which indicates not extremely thick or really thin. It must also have adequate radius on its corner, which should to become a minimal of wall thickness or greater.

The specific requirements on precision molding machine:

• Injection pressure ? 25 MPa;
• Injection speed ? 300 mm/s;
• Product size precision 0.001mm;
• Product quality standard deviation coefficient (velocity of variation) ? 0.1%;
• Opening and closing mould position accuracy:

opening ? 0.03 mm, closing ? 0.01

• Injection position accuracy (holding pressure end point) ? 0.03 mm;
• Equilibrium degree of force in tie bar ? 1%;
• Pre-plastic position accuracy ? 0.03mm;
• Stationary mould and movable mould’s degree of balance
• ? 0.03 mm when clamping force is zero;
• ? 0.005 mm when clamping force is max;
• Temperature control accuracy of barrel and screw ? ± 0.5 ?;

The focus of precision injection molding technology:

• Clamping force

In precision injection molding process, machine generally requires a high injection pressure (?250 MPa), or it would be difficult to molding. However, note that, in general, precision injection molding products have relatively small dimensions and thickness, so not all products have high requirements on clamping force. Conversely, if the clamping force is too large, or uneven in four corners, or instable, it will lead to uneven molding on mould and then ultimately affect the quality of molding product. Precision injection molding process requires adjusting clamping force reasonable, conveniently and accurately, overcoming the length and size differences caused by the clamping force unit deformation and the problem of unstable clamping force caused by room temperature and mould temperature’s changes.

• Plasticizing quality

Uniformity of plasticizing not only affects the product molding quality, but also affects the resistance when melting plastic flow through the gate. In order to get a uniform plasticizing, it is necessary to design special screw and plasticization technology. In addition, the barrel temperature should be precisely controlled.

• Measurement accuracy

To make the plastic product maintains a high stability, the injection plastic inject into the cavity each time must be equal, that means the screw reset accuracy when feeding must be the same. But in fact, the screw reset positions are unable to maintain the same completely, the larger diameter of the screw, the larger of system inertia, and the more difficulty for controlling position accuracy. We generally control the screw reset accuracy in 0.3 mm, perfectly in 0.2 mm.

• Injection speed

Injection speed is an important indicator in precision injection molding machine as there is a time difference from the hot melting plastic start injecting into cavity to finish injection. During this time, the hot melting plastic begin cool, to make the material at the gate and in the mould cavity cool uniformly, it should choose high speed injection. And to improve injection speed, you must configure one or more accumulator which can release energy quickly to shorten the time difference. It is advantageous for precision injection molding to improve the original injection speed more than 3 times, reaching 300~800 mm/s.

• Injection pressure

Precision injection molding requires a large injection pressure to increase the plastic density, reduce shrinkage, and ensure the product precision. However, the injection pressure is not the bigger the better, over pressure will have flash. In the best injection pressure, the injection cycle time should not more than 0.05 seconds.

• Holding pressure

Holding pressure has a great impact on precision plastic. Accurately, holding pressure can make a nice feeding, reduce the plastic deformation and control the product precision. The stability of holding pressure decide the molding precision, unchangeable screw end position determine the holding effect.

• Mould temperature

For precision injection molding, the mould cavity temperature should be controlled in ±1?, which must use PID control. But for ultra-precision injection molding, this is not enough, more advanced method is to use FUZZF control (fuzzy control).

If you are interested in Injection Mold Maker but are not sure where to go to find it, then you should know that there are a few options in particular that you should be taking into consideration. By choosing these particular Injection Mold Maker companies over any other, you are going to be ensuring that you receive the best quality and value possible, which is obviously very important to anyone.

Bring into Play the Use of an Injection Mold Makers:

The Injection Mold Maker Resource is considered as being the Internet’s best source when it comes to information on machines and resins. The injection molding process and plastics industry has truly become an incredible, multi-billion dollar industry, and injection molding has made possible the cheap and durable construction of various different consumer and industrial items which have had a profound impact on society.

They are a company whose goal is to educate both customers and engineers as much as possible by providing information regarding manufacturers, resins, materials, and anything else that is related to injection molding.

The Equipment Used in Injection Molding:

Their products include mold waxes, polyvinyl alcohol or PVA film forming barrier solutions and mold polishes and buffing compounds, and mold cleaners. What is good about these products is that most of them are environmentally friendly and only contains ingredients that are non-hazardous.

Injection Mold Makers is a method of molding in which the molding material is first placed in an open, heated mold cavity. The mold is then closed with a strong top force or plug member, and pressure is put on to force the material into contact with all of the mold areas, and then proper heat and pressure are maintained until the molding material has completely cured.

The Injection Mold Makers process employs plastic resins in a partially cured stage, either in the form of granules, putty-like masses, or preforms. It is also important to understand that Injection Mold Makers is an incredibly high volume, high pressure molding method that is suitable for a variety of different purposes, including the molding of complex, high strength fiberglass reinforcement.

• Choose the right type of plastic injection molding machine: make decision by the products and plastic

The plastic injection molding machine has a lot of types, so at the beginning, you should determine that what kind or which series of plastic injection molding machine is fit for the product. For example, for thermoplastic plastic or Bakelite resin or PET, the product is single color, two-color, multi-color, laminated or blending. In addition, some product requires high stability (closed loop), high precision, high injection speed, high injection pressure and rapid production (multi-loop) and so on.

• Able to put it on: the size of mold determine whether the internal spur of large column, the mold thickness, the minimum mold dimension and the mold plate size of plastic injection molding machine are suitable or not, to make sure that it is able to put mold on.

The mold width and height must be less than or at least less than the internal spur of large column; The mold width and height must in the mold plate size range; the mold thickness should be between the thickness of plastic injection molding machine; The mold width and height must be fit with the minimum mold size recommended by the plastic injection molding machine.

• Able to put it out: the mold and product judge whether the “Opening Stroke” and “Ejector Stroke” are enough to remove the finished product.

The opening stroke should at least larger than the product height along the opening direction more than twice, including the length of vertical sprue; ejector stroke should long enough to eject the finished product.

• Able to maintain locked: the product and plastic determine the tonnage of “clamping force”.

When the raw materials inject into the mold cavity in a high pressure, it will create a bulging force, so the clamping unit of the plastic injection molding machine should provide sufficient “clamping force” so that the mold was not subject to distraction. The need of clamping force is calculated as follows:
Clamping force = projected area of product in the direction of opening and closing mould (cm2) ×the number of mold cavity×in-mold pressure (kg/cm2);
Projected area of product in the direction of opening and closing mould is generated by the product appearance size.
In-mold pressure is different with different materials, generally take 350-400 kg/cm2.
The machine clamping force is usually greater than 1.17 times of the bulging force.

• Enough injection quantity: the weight of product and the number of mold cavity determine the “injection quantity” and select the appropriate “screw diameter”.

For stability purpose, the injection volume required for more than 1.35 times of the product, which means the product weight should less than 75% of the injection amount.

• Good injection: plastic determine “screw compression ratio” and “injection pressure” and other conditions.

Some plastic requires a higher injection pressure and appropriate screw compression ratio for a good molding. So when choosing screw, it should considered about the demand of injection pressure and the problems of compression ratio. In general, smaller diameter screw provides higher injection pressure.

• High injection speed: confirm the injection speed.

Some product requires a high injection speed to stabilize the injection molding, such as ultra-thin wall product. In this case, it is necessary to make sure that whether the injection speed and injection rate are enough or not, and whether accumulator and closed-loop control are necessary or not. Generally speaking, in the same condition, a screw in the plastic injection molding machine with high injection pressure has a lower injection speed, on the contrary, a screw with low injection pressure has a higher injection speed. So when choosing the screw diameter, injection volume, injection pressure, and injection rate (injection speed) should be cross considered.

Die-casting handle

1. Full Service Production

 . Provide casting, stamping, CNC machining, heat treating,

   and finish treatment

2. Engineering Support

 . Tooling and gauging design

 . 3D computer-aided-manufacturing (cam)

3. Quality Assurance

 . Incoming material inspection

 . Statistical process control

 . Inspection before shipment

4. Material Apply

 . Stainless steel, carbon steel, alloy steel, aluminum

   alloy, brass alloy, and ductile iron

5. OEM and ODM Manufacture

 . Manufacture custom designed products to meet customers

   Specifications

6. Small Order Acceptable and Prompt Delivery

• Material: aluminum alloy
• Die Casting is made of Aluminum Alloy, powder coated process surface,suitable for machinery part,OEM Orders are Accepted
• Product weight: 0.010 to 8kg/piece
• Software for drawing: pro/E, auto CAD, solid work 2007, UG, CAD and Solidworks flow analysis
• Further machining work: turning and cutting, milling, grinding, drilling and reaming and threading
• Surface finish process: polishing shot blasting, chromate plating, power coated and anodizing
• Parts range: auto parts, electronic parts, furniture parts, home appliance and other industrial uses
• Processes: CAD service, metal processing, surface plating, QC testing and packing
• Customized drawings, specifications and samples are welcome
• OEM/ODM orders are welcome
• All brands and trademarks used are for reference only

• high speed injection molding reduce the cycle time, increased the production per unit time.
• reduce the unit plastic pcs’ electricity consumption, reduce the unit plastic component’s cost.
• reduce the labor cost to reduce the unit plastic component’s cost.
• reduce the water, production space.
• shortened the delivery time.

From 2010 July to the end of the year, Chinese goverment have carried out the new policy of energy saving, this policy has limited too much enterprises which have huge energy consumptions. Many plastic injection molding companies are facing terrible problems.  Because the limitation to the usage of  electricity, they have to stop the production time to time, each day, their machine can only run for 2 or 5 hours. It reduce the production capacity by 70 to 90%.