Mold-Making Handbook

About the Book

Contributors

Editor’s Preface to the 3rd edition

Contents

1 Molds for Various Processing Methods

1.1 Injection Molds

1.1.1 General

1.1.2 Injection Molding Process

1.1.3 Design of the Molded Part

1.1.4 Basic Mold Structure

1.1.5 Types of Ejection

1.1.6 Gate Technology

1.1.7 Venting of the Cavity

1.1.8 Temperature Control

1.1.9 Special Designs

1.1.5.1 Products without Undercuts

1.1.5.2 Products with External Undercuts

1.1.5.3 Product with Internal Undercuts

1.1.5.4 Products with Internal Threads

1.1.6.1 Gate Design

1.1.6.2 Solidifying Runner, Remaining at the Molded Part

1.1.6.3 Automatically Separated Runner

1.1.6.4 Pass Through Channels

1.1.6.5 Hotrunner Molds

1.1.6.6 Hotrunner Nozzles

1.1.9.1 Stack Molds

1.1.9.2 Injection-Compression Molds

1.1.9.3 Multi-Component Technology

1.1.9.4 Outsert Technology

1.1.9.5 Molds for Thermosets and Elastomers

1.2 Compression and Transfer Molds

1.2.1 Introduction

1.2.2 Compression Molds

1.2.3 Transfer Molding

1.2.4 Making Compression Molds

1.2.5 Mold Design

1.2.6 Sheet Molding Compound (SMC)-Molds

1.2.7 GMT/LFT Molds

1.2.8 Practical Example

1.2.2.1 General Information

1.2.2.2 Requirements

1.2.2.3 Components of a Compression Mold

1.2.3.1 General

1.2.3.2 Requirements

1.2.3.3 Structure of a Transfer Mold

1.2.4.1 Machining

1.2.5.1 Types of Molds

1.2.5.1.1 Small-Series Mold

1.2.5.1.2 Test Mold

1.2.5.1.3 Standard Mold Unit

1.2.5.1.4 Conventional Compression Mold

1.2.5.2 Structural Mold Designs

1.2.5.2.1 Positive Mold

1.2.5.2.2 Positive Mold with Lands

1.2.5.2.3 Multi-Cavity Mold with a Common Loading Chamber

1.2.5.2.4 Multi-Cavity Mold with Individual Loading Chambers

1.2.5.2.5 Mold with Lateral Core Puller

1.2.5.2.6 Split Mold

1.2.5.2.7 Hinged Split-Cavity Mold

1.2.5.2.8 Mold with Inserts

1.2.5.2.9 Unscrewing Mold

1.2.5.3 General Aspects

1.2.6.1 Introduction

1.2.6.2 Mold Design

1.2.6.2.1 Mold Alignment

1.2.6.2.2 Ejector Mechanism

1.2.6.2.3 Undercuts

1.2.6.2.4 Heating

1.2.7.1 Introduction

1.2.7.2 Process Technology

1.2.7.2.1 Pressure Forming

1.2.7.2.2 Flow Molding

1.2.7.3 Mold Construction

1.3 Molds for Polyurethane Products

1.3.1 Products, Processes, Applications, Shrinkage, and Mold Carriers

1.3.2 Molds for Low-Density PUR Foam

1.3.3 Molds for PUR Integral Skin Foams (Self-Skinning Foams)

1.3.4 Molds for Microporous PUR Products

1.3.5 Molds for PUR Casting Systems

1.3.1.1 Material Components, Processing, Applications

1.3.1.2 Shrinkage

1.3.1.3 Mold Carriers

1.3.2.1 Processing Parameters

1.3.2.1.1 Reaction Temperature

1.3.2.1.2 Internal Pressure in Molds

1.3.2.2 Filling Technology

1.3.2.2.1 Open-Mold Filling Method

1.3.2.2.2 Closed-Mold Filling Method

1.3.2.3 Venting

1.3.2.4 Mold Design

1.3.2.4.1 Clamping

1.3.2.4.2 Closing and Opening Mechanism, Demolding Aids

1.3.2.4.3 Fastening of Inserts

1.3.2.5 Molds for Flexible PUR Foams [7, 8]

1.3.2.6 Molds for Semirigid Foams

1.3.2.7 Molds for Rigid PUR Foams

1.3.3.1 Influence of Processing on Mold Design

1.3.3.1.1 Temperature control

1.3.3.1.2 Sealing at Parting Line, Ejectors, and Side Cores/Sliders

1.3.3.2 Gating

1.3.3.3 Venting

1.3.3.4 Molds for Flexible Integral Skin Foams

1.3.3.5 Molds for Semirigid Integral Skin Foams

1.3.3.6 Molds for Rigid Integral Skin Foams

1.3.4.1 Molds for Flexible, Microporous PUR Products

1.3.4.2 Molds for Tough, Rigid, Microporous PUR (RIM) Products

1.3.4.3 Molds for Rigid, Microporous PUR Products

1.4 Blow Molds

1.4.1 Process Description

1.4.2 Extrusion Blow Molds

1.4.3 Injection Blow Molding and Dip Blow Molding

1.4.4 Use of Computers for Blow Molding

1.4.1.1 Different Types of Blow Molding Processes

1.4.1.2 Extrusion Blow Molding Technology

1.4.1.2.1 Continuous Extrusion

1.4.1.2.2 Intermittent Parison Generation

1.4.1.2.3 Parison Generation

1.4.1.2.4 Different Blow Up Methods

1.4.1.2.5 Special Procedures

1.4.2.1 Mold Construction

1.4.2.1.1 Prototype Blow Molds Made from Cast Resin

1.4.2.1.2 Prototype Blow Molds with Metal-Coated Model and Metal-Filled Cast Resin

1.4.2.1.3 Blow Molds Made from Cast Metals

1.4.2.1.4 Milled Prototype Molds

1.4.2.1.5 Production Blow Molds

1.4.2.2 Construction Guidelines

1.4.2.2.1 Alignment of Blow Mold

1.4.2.2.2 Cutting Edges

1.4.2.2.3 Clamp Stops

1.4.2.2.4 Venting

1.4.2.3 Blow Mold Cooling

1.4.2.4 Accessories for Blow Molds

1.4.2.5 Integrated Postmolding Processes

1.4.2.5.1 Postcooling with a Cooling Fixture

1.4.2.5.2 Manufacturing the Finished Product in the Blow Molding Machine

1.5 Molds for Thermoforming

1.5.1 General Information

1.5.2 Process in Thermoforming

1.5.3 The Mold and the Format Parts

1.5.4 Positive or Negative Forming?

1.5.5 Design Guidelines for Thermoforming Molds

1.5.6 Substructure of Hot Forming Molds

1.5.5.1 Material Choice

1.5.5.2 Molding Shrinkage

1.5.5.3 Draft Angles

1.5.5.4 Radii

1.5.5.5 Surface Roughness

1.5.5.6 Assisting Plug

1.5.5.7 Venting Design

1.5.5.8 Cavities

1.5.5.9 Avoidance of Edge Webbing in Positive Molds

1.5.5.10 Vacuum Losses when Designing Mold Bottom Wrongly

1.5.5.11 Suggestions for Temperature Control of Hot Forming Molds

1.5.6.1 Vacuum Forming on a Sheet Processing Machine

1.5.6.2 Pressure Air Forming with Forming/Punching Mold with Shear Cutting

1.5.6.3 Pressure Air Forming with Forming/Punching Mold with Steel Rule Die

1.6 Rotational and Slush Molds

1.6.1 Process Description

1.6.2 Strength of a Rotomolded Part

1.6.3 Mold Requirements

1.6.4 Nomenclature of Rotational Molds

1.6.5 Types of Molds

1.6.6 Mold Construction

1.6.7 Mold Peripheral

1.6.8 Post-Processing of Rotomolded Plastic Products

1.6.9 Electroplated Mold for the Slush Molding Process

1.6.5.1 Prototype Rotational Molds

1.6.5.2 Sheet Steel Rotational Molds

1.6.5.3 Aluminum Rotational Molds

1.6.5.4 Electroplated Molds

1.6.6.1 Closing and Clamping of Molds

1.6.6.2 Mold Wall Thickness and Centering

1.6.6.3 Mold Surfaces and Changes

1.6.7.1 Mold Venting

1.6.7.2 Non-Permanent Release Agent

1.6.7.3 Mold Coating (Permanent Release Coatings)

1.6.7.4 Threads

1.6.7.5 Other Inserts

1.6.8.1 Openings

1.6.8.2 Decoration of Rotomolded Plastic Products

1.7 Molds for Thermoplastic Foams

1.7.1 Thermoplastic Foams

1.7.2 Conventional Molding

1.7.3 Mold Construction

1.7.4 Block Molds

1.7.2.1 Procedure Description

1.7.2.1.1 Filling

1.7.2.1.2 Expanding and Fusing

1.7.2.1.3 Cooling and Stabilizing

1.7.2.1.4 Demolding

1.7.2.2 Special Procedure

1.7.2.2.1 Process with Non-Perforated Molds

1.7.2.2.2 Low Temperature Horizontal (LTH) Process

1.7.2.2.3 Transfer Technology

1.7.2.2.4 Multiple-Density-Process

1.7.3.1 Essential Requirements on the Mold Construction

1.7.3.2 Mold Materials

1.7.3.3 Mold Equipment

1.7.3.4 Special Mold Designs

1.7.3.4.1 Mono-Block Molds

1.7.3.4.2 Molds with Adjustable Walls (Gradually or Continuously) for Insulation Plates and Small Blocks

1.7.3.4.3 Mold for the Thin-Walled Technology

1.7.4.1 Process Discription

1.7.4.2 Constructive Design

1.8 Molds for Continuous Fibre Reinforced Polymer Composites

1.8.1 General Objective

1.8.2 Molds for the Vacuum-Autoclave-Technology

1.8.3 Continuous Fiber-Reinforced Thermoplastics

1.8.4 Molds for the Resin Injection

1.8.5 Molds for the Winding Technology

1.8.2.1 General Objective

1.8.2.2 Prepreg-Low Pressure-Autoclave Technology

1.8.2.3 Molds for the “Soft Core” Technology

1.8.2.3.1 Master Model

1.8.2.3.2 Mold Cavity

1.8.2.3.3 Product Substitute

1.8.2.3.4 Elastic Mat

1.8.2.3.5 Manufacturing of Products

1.8.2.4 Molds for the Hard-Core Technology

1.8.2.4.1 Mold Construction and Materials

1.8.2.4.2 Manufacture of Products

1.8.2.5 Molds for Automated Tape Laying

1.8.3.1 General Information and Fundamentals of the Processes

1.8.3.2 Molds for Semifinished Part Production

1.8.3.2.1 General Information and Fundamentals of the Processes

1.8.3.2.2 Molds for Flat Semifinished Plates

1.8.3.2.3 Molds for Profiles

1.8.3.3 Molds for Forming Technology (Thermoforming)

1.8.3.3.1 General Information and Fundamentals of the Processes

1.8.3.3.2 Molds for the Stamp Forming

1.8.3.3.3 Molds for the Diaphragm Technology

1.8.3.3.4 Molds for Sandwich Components

1.8.3.3.5 Molds for the Process Step Integration

1.8.3.4 Molds for the Welding Technology

1.8.4.1 General Information and Fundamentals of the Process

1.8.4.2 Molds for the Preform Technology

1.8.4.2.1 Binder-Forming Molds

1.8.4.2.2 Stitching Technology Molds

1.8.4.3 Molds for Vacuum Assisted Processes

1.8.4.3.1 Molds with a Fixed and Flexible Mold Half

1.8.4.3.2 Molds with Two Fixed Mold Halves

1.8.4.4 Molds for Pressure-Assisted Processes

1.8.4.5 Molds for Hollow Components

1.8.5.1 General Information and Fundamentals of the Process

1.8.5.2 Molds for Rotationally Symmetrical Components

1.9 Molds for Elastomer Processing

1.9.1 Compression Molding (CM)

1.9.2 Transfer Molding (TM)

1.9.3 Injection Molding (IM)

1.9.4 Additional Processes

1.9.5 Mold Making

1.9.4.1 Process Combinations

1.9.4.2 Gate Systems

1.9.5.1 Types of Molds

1.9.5.2 Mold Development

1.10 Micro Injection Molds

1.10.1 General Information

1.10.2 Design

1.10.3 Manufacture

1.10.4 Manufacturing Technologies

1.10.5 Injection Molding Machine

1.10.6 Mold Maintenance

1.10.7 Outlook

1.10.1.1 Injection Molding Process

1.10.1.2 Molded Part Design

1.10.1.2.1 Cooperation with Customers

1.10.1.3 Materials for Injection Molded Parts

1.10.2.1 The Micro-injection Mold

1.10.2.1.1 Gate

1.10.2.1.2 Demolding and Ejection

1.10.2.1.3 Venting

1.10.2.1.4 Mold Guiding and Centering

1.10.2.1.5 Temperature Control and Cooling

1.10.2.2 Special Procedures and Alternative Processes

1.10.2.2.1 Variotherm

1.10.2.2.2 Insertion Technology

1.10.2.2.3 Multi-Component and Assembly Injection Molding

1.10.2.2.4 Compression Injection Molding

1.10.2.2.5 Hot Embossing

1.10.2.3 Environment and Continuing Processes

1.10.3.1 Construction

1.10.3.1.1 Materials for Constructional Parts

1.10.3.1.2 Standard Parts

1.10.3.2 Cavity Stacks

1.10.3.2.1 Material for Cavity Stacks

1.10.4.1 In General

1.10.4.1.1 Mechanical Manufacturing Technologies

1.10.4.1.2 Alternative Manufacturing Processes

1.10.4.1.3 Surface Treatment and Refining

1.10.4.1.4 Quality Assurance

1.11 Prototype, Small and Pre-Series Molds

1.11.1 Introduction

1.11.2 Indirect Prototype Molding

1.11.2.1 Vacuum Casting Polyurethane (PU) on silicone molds

1.11.2.1.1 Vacuum Casting PU Process

1.11.2.1.2 Manufacture of Silicone Molds PU

1.11.2.2 Vacuum Casting Polyamide (PA) through silicone molds

1.11.2.3 Synthetic Resin Molds

1.11.2.3.1 Polyurethane Casting with Synthetic Resin Molds

1.11.2.3.2 Manufacture of Synthetic Resin Molds

1.11.2.4 Manufacture of Synthetic Resin Molds for Injection Molding

1.11.2.5 Molds Manufactured through Generative Manufacturing Procedures on the Example of LaserCUSING®-Technology

1.11.2.6 Aluminum Molds

1.11.2.6.1 Manufacture of Aluminum Molds

1.11.2.6.2 Aluminum Molds with LaserCUSING® Loose Parts

1.11.2.6.3 Aluminum Materials

2 Mold Design

2.1 Design Process

2.1.1 Introduction

2.1.2 Simulation for Injection Mold Making

2.1.1.1 Injection Molds

2.1.1.2 Phases of the Mold Design

2.1.1.3 From the Offer to the Design

2.1.1.4 The Design Process in Injection Molds

2.1.2.1 General Information

2.1.2.2 The Types of Models

2.1.2.3 The Flow Pattern

2.1.2.4 Shrinkage and Warpage

2.1.2.5 Thermal Design

2.1.2.6 Summary

2.2 Standardization and Standards

2.2.1 Standardization for Injection Molding and Hot Runner Molds

2.2.2 Standards in Mold Making

2.2.2.1 Molds

2.2.2.2 Standardized Guide Element in Mold Making

2.2.2.3 Standards for Demolding

2.2.2.4 Temperature Control

2.3 Hot and Cold Runner Technology

2.3.1 Advantages of Using the Hot Runner Technology

2.3.2 Design of Hot Runner Systems and Hot Halves

2.3.3 Application Areas and Examples

2.3.4 Hot Runner Manifold Systems, Wired Systems, and Hot Halves

2.3.5 Hot Runner Control Technology

2.3.6 Cold Runner Systems

2.3.3.1 Hot Runner Solutions for Packaging Parts, Closures, and Miscellaneous Polyolefin Applications

2.3.3.2 Hot Runner Solutions for Technical Components

2.3.3.3 Hot Runner Solution for Small and Micro Injection Molded Parts

2.3.3.4 Hot Runner Solutions for Multi-Point Gating through Nozzles and Multi-Nozzles

2.3.3.5 Hot Runner Solutions with Needle Valve

2.3.6.1 Function and Advantages

2.3.6.2 Processable Materials

2.3.6.3 Mold Technology

2.3.6.4 Demolding

2.3.6.5 Mold Temperature Control

2.4 Temperature Control of Injection Molds

2.4.1 Tasks and Goals of the Mold Temperature Control

2.4.2 Influence of Processing Temperatures on the Cooling and Cycle Time

2.4.3 Cavity Temperature

2.4.4 Influence of Temperature Control on the Molded Part Properties

2.4.5 Requirements for the Temperature Control System

2.4.6 Temperature Control Channels

2.4.7 Flow Principle

2.4.8 Practical Designs of Conventional Temperature Control Options

2.4.9 New Temperature Control Technologies

2.4.10 Thermal Mold Design

2.4.11 Position of the Temperature Sensor for External Temperature Control

2.4.7.1 Series Temperature Control

2.4.7.2 Parallel Temperature Control

2.4.8.1 Flat Temperature Control

2.4.8.2 Temperature Control of Molded Part Corners

2.4.8.3 Temperature Control of the Core

2.4.8.3.1 Temperature Control Tubes

2.4.8.3.2 Separating Plate (Deflection Bar)

2.4.8.3.3 Spiral Cores

2.4.8.3.4 Heat Pipe

2.4.8.4 More Conventional Temperature Control Options

2.4.8.4.1 Circumferential Application Temperature Control

2.4.8.4.2 Inserts Made from Different Materials

2.4.9.1 Contour-Depending Temperature Control

2.4.9.1.1 Vacuum Brazing Technology

2.4.9.1.2 Selective Laser Sintering (SLS)

2.4.9.2 CO2 Temperature Control

2.4.9.2.1 CO2 Temperature Control with Sintered Material

2.4.9.2.2 CO2 Temperature Control with Conventional Steel

2.4.9.3 Dynamic Temperature Control

2.5 Innovative Mold Technologies

2.5.1 Coating Technology – Design Surfaces through Combined Surface and Coating Technologies

2.5.2 Temperature Control Technology – Inductive Heating of Injection Molds

2.5.3 Vacuum Technology – Alternative Possibilities, Optimization of Surfaces

2.5.4 Mold Technology – Flexible Sealing Elements for the Flash- and Damage-Free Encapsulation of Inserts

3 Materials for Mold Making

3.1 Plastic Mold Steels

3.1.1 Introduction

3.1.2 Steel making and processing

3.1.3 Overview of plastic mold steels

3.1.4 Concluding comment

3.1.2.1 Steelmaking

3.1.2.2 Heat treatment

3.1.2.3 Machining

3.1.2.4 Surface machining

3.1.2.5 Quality assurance

3.1.3.1 Pre-hardened plastic mold steels

3.1.3.2 Through-hardening plastic mold steels

3.1.3.3 Corrosion-resistant plastic mold steels

3.1.3.4 Plastic mold steels for case hardening

3.1.3.5 Precipitation hardening plastic molds steels

3.1.3.6 Nitriding steels

3.2 Aluminum Alloys

3.2.1 Introduction

3.2.2 Mold Materials

3.2.3 Manufacture of Aluminum Molds

3.2.4 Applications

3.2.2.1 Casting Materials

3.2.2.2 Wrought Materials

3.2.2.3 Mechanical Properties and Design Guidelines

3.2.2.4 Corrosion

3.2.2.5 Friction and Wear Resistance

3.2.3.1 Abrasive Procedures

3.2.3.1.1 Machining

3.2.3.1.2 Grinding

3.2.3.1.3 Electrical Discharge Machining (EDM) or Wire EDM

3.2.3.1.4 Etching

3.2.3.2 Welding

3.2.3.3 Casting

3.3 Copper Alloys-Nonferrous Metals

3.3.1 Properties

3.3.3 Surfaces

3.3.4 Summary

3.3.1.1 Strength Properties

3.3.1.2 Thermal Properties

3.3.2.1 Turning

3.3.2.2 Milling

3.3.2.3 Drilling

3.3.2.4 Threading

3.3.2.5 Reaming

3.3.2.6 EDM

3.3.2.7 Welding

3.3.3.1 Polishing

3.3.3.2 Coating

3.3.3.3 Structuring

4 Manufacturing and Machining Methods

4.1 Mold Manufacturing

4.1.1 Introduction

4.1.2 Design

4.1.3 Data Model

4.1.4 Data Transfer in Mold Making

4.1.5 Feedback/Communication

4.1.6 Design

4.1.7 Programming

4.1.8 Machining

4.1.9 Dimensional Inspection

4.1.10 Drilling/Deep Hole Drilling

4.1.11 Electric Discharge Machining

4.1.12 Surface Finishing

4.1.13 Assembly

4.1.14 Trials

4.1.15 Optimization Process and Finishing

4.1.2.1 Development

4.1.2.2 Visualizing

4.1.2.3 Cubing Model

4.1.2.4 Stereolithography

4.1.3.1 Data Feedback

4.1.3.2 Completion of Product Data

4.1.4.1 Verifying of Data Quality

4.1.4.2 Feasibility Studies

4.1.6.1 System Environment

4.1.6.2 Releases

4.1.7.1 Software

4.1.7.2 Strategies

4.1.7.3 Choice of Machinery

4.1.8.1 Tooling

4.1.8.2 Unattended Operation

4.1.8.3 Releases

4.2 Electric Discharge Machining (EDM)

4.2.1 Introduction

4.2.2 Physical Processes

4.2.3 Tolerances and Key Data

4.2.4 Die-Sinking EDM

4.2.5 Wire-cut EDM

4.2.6 Combined and Special Processes

4.3 Galvanized Inserts and Molds

4.3.1 General Information

4.3.2 Process Description

4.3.3 Galvanized Materials

4.3.4 Model Materials and Model Design

4.3.5 Clamps and Mounting Brackets

4.3.6 Finishing and Installation of Galvanized Injection Inserts

4.3.7 Efficiency and Service Life

4.3.8 Galvanized Molds for Other Plastics Processing Methods

4.3.9 Negative-Stamping Deep Drawing Process (In-Mold Graining)

4.3.8.1 Molds for Processing Polyurethane Foam

4.3.8.2 PUR Spray Molds

4.3.8.3 Laminating Molds for the Aerospace Industry

4.4 Polishing Technology in Mold Making

4.4.1 General Information

4.4.2 Definition of the Term Surface Roughness

4.4.3 Systematic Polishing Technique

4.4.4 Polishing Behavior-Influencing Factors

4.4.5 Polishing Technologies

4.4.6 Ultrasonics

4.4.7 Electric Discharge Machining/Erosion for Brilliant Surfaces

4.4.5.1 For Superfinishing (Polishing) Surface Preparatory Leveling Technology

4.4.5.2 Lapping

4.4.5.3 Polish Lapping

4.4.5.4 Polishing

4.5 Heat Treatment and Surface Finishing Techniques

4.5.1 Introduction

4.5.2 Heat treatment of plastic mold steels

4.5.3 Surface finishing

4.5.2.1 Hardened and tempered plastic mold steels

4.5.2.2 Through-hardening steels

4.5.2.3 Corrosion-resistant steels

4.5.2.4 Case-hardening steels

4.5.2.5 Nitriding steels

4.5.2.6 Maraging mold steels

4.5.2.7 General recommendations for heat treatment

4.5.3.1 Thermal processes

4.5.3.1.1 Flame hardening

4.5.3.1.2 Laser hardening

4.5.3.2 Thermo-chemical processes

4.5.3.2.1 Case-hardening

4.5.3.2.2 Nitriding

4.5.3.2.3 Gas nitriding

4.5.3.2.4 Plasma nitriding

4.5.3.2.5 Boriding

4.5.3.3 Electrochemical processes

4.5.3.3.1 Hard chrome plating

4.5.3.3.2 Nickel plating

4.5.3.4 Chemical and physical processes

4.5.3.4.1 CVD coating

4.5.3.4.2 PACVD coating

4.5.3.4.3 PVD coating

4.5.3.5 Comparing and Selecting Surface Treatment Processes

4.6 Surface Structuring

4.6.1 The Photochemical Etching Technology

4.6.2 Requirements on the Mold Surface and Construction

4.6.3 Special Processes

4.6.4 The Execution of the Order

4.6.1.1 Introduction

4.6.1.2 Why Structuring?

4.6.1.3 From the Structure Template to the Film

4.6.2.1 Materials and the Selection of Materials

4.6.2.1.1 Steel

4.6.2.1.2 Aluminum and Other Materials

4.6.2.1.3 Heat Treatment and Surface Refinement

4.6.2.1.4 Grain Depths and Tolerances

4.6.2.1.5 The Gloss Level in the Mold and in the Molded Part

4.6.2.2 Processing Methods and Repair Technology

4.6.2.3 Draft Angles, Open Spaces, and Surface Preparation

4.6.2.4 Contour Changes by Welding of Inserts

4.6.2.5 Contour Changes by Shrinking Inserts

4.6.2.6 Structure Hardening, Fiber Orientation, Band-Type Formation

4.6.2.7 Etching Test

4.6.3.1 Design Types and Etching Combinations

4.6.3.2 Limitations of the Processing Technology

4.6.3.3 New Technologies

4.6.4.1 Supply

4.6.4.2 Information about the Grain Area and the Mold

4.6.4.3 Concluding Remark

4.7 Rapid Prototyping in Mold Making

4.7.1 Rapid Tooling

4.7.2 Fundamentals of the Generative Manufacturing Processes

4.7.3 Generative Processes for Mold Making

4.7.4 Machines for Generative Mold Making

4.7.5 Examples

4.7.6 Delimitation to Non-Generative Manufacturing Processes

4.7.7 Names and Links

4.7.2.1 Process Principle

4.7.2.2 Data Flow and Data Formats

4.7.2.3 Properties of Generative Components

4.7.2.4 Definitions for Rapid Tooling

4.7.3.1 Polymerization-Stereolithography

4.7.3.2 Sintering and Melting

4.7.3.3 Layer-Laminate Process

4.7.3.4 Extrusion Process

4.7.3.4.1 3D Printing

4.7.5.1 Prototype Tooling

4.7.5.2 Direct Tooling

5 Ordering and Operation of Molds

5.1 Molds in the Offer Phase

5.1.1 Introduction

5.1.2 The Planning of Molds

5.1.3 Costing in Mold Making

5.1.4 Summary

5.1.2.1 Adjustment Process of Component and Mold

5.1.2.2 Design of the Mold under Consideration of the Product Life Cycle

5.1.2.3 Checklist for the Mold Specification

5.1.3.1 Various Methods for Costing

5.1.3.2 Simplified Costing in the Bidding and Design Phase

5.1.3.2.1 Estimated Value Technology

5.1.3.2.2 Reference Value Methodology

5.1.3.2.3 Cost Element Methodology/Variable Costing

5.1.3.2.4 Detail Calculations/Post-Calculations

5.2 Setup and Control of Molds

5.2.1 Requirements for Effective Quality Assurance

5.2.2 Mold Sensor Systems Overview

5.2.3 Data Acquisition and Electronics

5.2.4 Setup and Optimization

5.2.5 The Process Monitoring

5.2.6 Factory-Wide Networking and Monitoring

5.2.7 Real-Time Controls in the Injection Molding Process

5.2.8 The Control of the Injection Molding Process

5.2.9 Outlook

5.2.2.1 Mold Cavity Pressure Sensors

5.2.2.2 The Measuring Principle

5.2.2.3 Cavity Temperature Sensors

5.2.2.4 Sensor Position

5.2.2.5 Quick Connectors

5.2.4.1 Cavity Pressure

5.2.4.2 The Importance of the Cavity Temperature Curve

5.2.4.3 Switchover to Holding Pressure

5.3 Wear on Injection Molds

5.3.1 Introduction

5.3.2 Tribological Fundamentals

5.3.3 Abrasion

5.3.4 Corrosion

5.3.5 Abrasive Wear of Mold Elements

5.3.6 Outlook and Development Trends

5.3.3.1 Forms of Damage on Molds and Hot Runners That Cause Molded Part Defects

5.3.3.2 Corrective Measures

5.3.4.1 Causes and Forms of Damage on Molds That Cause Molded Part Defects

5.3.4.2 Corrective Measures

5.3.5.1 Types of Damage on Mold Elements

5.3.5.2 Corrective Measures

5.4 Maintenance, Storage, Service

5.4.1 General Information

5.4.2 Maintenance, Wear Supply, Hardness

5.4.3 Inspection

5.4.4 Repair

5.4.5 Optimization

5.4.6 Storage

5.4.7 Maintenance and Servicing Costs

5.4.3.1 Time

5.4.3.2 Inspection Plan

5.4.4.1 Wear

5.4.4.2 Leakage

5.4.4.3 Breakage

5.4.4.4 Repair Measures

5.4.6.1 Preservation

5.4.6.2 Storage Location

5.4.6.3 Mold Labeling

5.4.6.4 Storage size

Subject Index