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Hybrid Tooling Vs P-20 Injection Molds

Hybrid Tooling Vs P-20 Injection Molds. Benefits of Hybrid Tooling as alternative to low volume production P-20 Steel tools or as an option to improve quality of parts off low cost Prototype tooling. 01/13/2007. Past Problems with AL Tooling. Hybrid vs P-20.

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Hybrid Tooling Vs P-20 Injection Molds

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  1. Hybrid ToolingVsP-20 Injection Molds Benefits of Hybrid Tooling as alternative to low volume production P-20 Steel tools or as an option to improve quality of parts off low cost Prototype tooling. 01/13/2007

  2. Past Problems with AL Tooling Hybrid vs P-20 • Aluminum Production Methods(past issues) • Block thickness limitations, especially with higher quality AL • Inconsistent ‘through-thickness hardness’ • Tool Shop Machining with Aluminum(past issues) • Previous or inferior grades of Aluminum would ‘gum up’ during machining • Lack of experience with Hot Manifold ‘set pressures’(leakage vs crush) • Injection Molding Processing with Aluminum(past issues) • Lack hot manifold use would result in higher mold pressures and higher stress on low quality aluminums • Excessive machine clamp pressure used from molder’s P-20 experience too much and not necessary for AL molding applications

  3. Recent Solutions for AL Tooling Hybrid vs P-20 • Aluminum Production Methods(recent improvements) • Very high quality AL is now available in block thickness of up to 24” • More uniform ‘through-thickness hardness’ • Tool Shop Machining with Aluminum(recent improvements) • High grades of AL (QC10, Alcamax, etc) have tight grain structure for outstanding machinability with small chips, outstanding surface finish & very fast CNC cutting speeds; This grain structure can be highly polished or textured • Increased experience with Hot Manifold ‘set pressures’(leakage vs crush) • Injection Molding Processing with Aluminum(recent improvements) • Frequent use of hot manifolds allow for reduced mold pressures & stress • Increasing knowledge of reduced clamp pressure needs and requirements for AL tooling combined with ability of new higher quality AL to withstand more stress and/or use of Hybrid tooling applications

  4. Benefits of Hybrid-AL Tooling Hybrid vs P-20 • Tool Design & Construction with Hybrid-AL • Position and number of water lines are less critical • Allows for placement of additional ejector pins where needed • Cutting speeds for AL are up to 10X’s faster than with P-20 steel • Heavier cuts with larger step-overs are possible • Stress Relief or Heat Treating not required • AL lends itself to Hybrid tooling with steel supports or grown insert details • Injection Molding Processing with Aluminum • Faster tool pre-heat and set-up time in molding press • Lighter molds (30-60%) are easier to move and less wear on equipment • Better Thermal Conductivity for wider process window, faster cycle times and improved part dimensional stability

  5. CAD of Hybrid Inserts to be Grown for Tooling Hybrid vs P-20

  6. Hybrid Inserts used for Tooling & Parts Hybrid vs P-20

  7. Hybrid Part Made Without Tooling Hybrid vs P-20

  8. Hybrid Inserts Grown for Tooling Hybrid vs P-20

  9. Hybrid Inserts used in Tooling Hybrid vs P-20

  10. Hybrid vs P-20 Hybrid Inserts used in Tooling

  11. Hybrid vs P-20 Hybrid Inserts used in Prototype Tooling Note: Hybrid tooling can also be used in low cost prototype tooling to increase tool durability and give special consideration to particular tool/part features. (As shown above)

  12. Hybrid vs P-20 Hybrid Inserts used in Production Tooling

  13. Hybrid vs P-20 Steel Support Pillars for Hybrid-AL Tools Example of steel support pillars used around the peripheral of tool cavity to increase longevity. • Reduces tool wear on parting line • Reduces clamp load on tool surface • Optional use of steel or grown inserts for lifters & slides

  14. Benefits of Hybrid-AL Tooling Hybrid vs P-20 • Hybrid-AL Tooling Benefits, what does it mean in the end? • Lower tooling investment cost of 15-30% over P-20 steel tools • Tool lead time improvement of 4-6 weeks over P-20 steel tools • Thermal Conductivity improvement of 4-5 times over P-20 steel tools • Wider processing window for more consistent parts • Dimensional Stability of parts greatly improved over P-20 steel tools • Faster Part Cycle Times provide $ savings as volumes increase • Limitations with Hybrid-AL Tooling • Higher volume part runs 250,000 pcs +, or Glass Filled resins • Molding facility education & awareness with Hybrid-AL tool processing • Cavity side welds (insert, weld, plate-coat or re-cut are available options)

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