Guide On NEW Auto-Unscrewing Mold for Internally Threaded Parts

We commonly find internal threads on plastic products that fit together, like drink-ware lids, plastic hardware, and bottle caps. Threads are delicate in nature, so molding these products need a touch different technique than the average plastic component. The tool must incorporate the unscrewing core for ejecting them out of the mold with no harm to the threads. Earlier, there was no other way than unscrewing components manually out of the core through hands to avoid threads stripping. And this results in extra time and labor, which means increased lead time and price. While some injection molding professionals still using this practice, there is a much better way called auto-unscrewing mold.

Now, we can easily mold internally threaded components in the tools that work automatically. It means that you can now get your products much faster and without any error. In this guide, we will show you how this new approach works and how it is benefiting us.

How Auto-Unscrewing Mold Works?

The process of the auto-unscrewing mold is simple and straightforward. It makes the entire process faster and helps us minimize extra labor costs. For a better understanding, we have broken down the working of automatic unscrewing mold technology into four different steps. Here is how the automatic unscrewing mold approach works:

1. First of all, we inject plastic into a tool. When the plastic cools down, the threaded core begins to unscrew. The hydraulic cylinder powers the mechanism of unscrewing through a pinion and rack.
2. In the second step, the rack works three gear sets after which it draws back the core into an ejector box.
3. The mold opens after the complete unscrewing of a threaded core and an ejector system drives the stripper plate frontward for part ejection.
4. Once the part ejects completely, the hydraulic cylinder converses and screw-threaded core again into the position of molding, and the procedure repeats.

This is how the auto-unscrewing mold process completes.

Threaded Plastic Parts

Threads in the plastic part permit fastening plastic parts to other plastic components/non-plastic components with the help of common fasteners. A plastic part may have threads both internally and externally. We can modify external threads to mold them without using any distinctive mold action. However, we require the help of the rotating core that unscrews the part when it comes to internal threads. We use unscrewing molds for plastic components with ridges or threads that we cannot inject easily with the conventional knockout method.

In such molds, we unscrew parts from molds for avoiding any thread damage. Molds unscrewing is still a highly complex injection mold method and requires high-speed movement and previously molded components efficiently for beginning the new cycle. They need exceptional technical savvy for building and maintaining. A manual or auto-unscrewing mold has a special design to ensure production for many years. This is why these molds are known as a great investment in the long run when producing parts in high volumes.

Injection Molding Undercuts

Undercuts means the features of a plastic component that we cannot remove from a mold in the mold’s opening direction. These features act as a barrier in the core’s direct removal. Consequently, necessitate an extra mold part like an internal core or side core lifter for forming the shape. We do not require these devices to remove smaller undercuts if the component can stretch or it can wrap around the plastic mold. If this is the case, the part’s wall opposite to the undercut needs to clear the core or mold before attempting ejection.

Whenever we have undercuts, we can use mold devices, like actions. The action device is a mold-traveling that goes in one direction vertical to the mold’s opening direction. The molding of the part’s undercut portion is possible by using the action. When the plastic mold opens, it will take a distance from the component. We can also use some other molding devices on components with undercuts. These include collapsing tooling and lifters. Use the lifter device when the undercut requirement is the segmented plastic.

Lifters are the mold’s components actuated by and attached to the ejector. It moves in an angular motion for freeing up the details of internal molding. Typically, they are attached between an ejector plate and an ejector retainer using a mechanism. It helps the fixed side to pivot or slide for compensating the lifter’s position movement as it reaches the needed angle. There are two reasons for which this angle holds immense importance.

Reason 1:

The first reason is that the ejector’s forward motion will put high pressure on the body of the lifter when the angle’s too exceptional. This pressure will create lifter binding and result in extreme wear or even a premature failure.

Reason 2:

Second, the travel of the ejector plate will be extreme when the angle’s too shallow. So, we must engage good expertise and careful engineering to avoid such issues.

We can save the lifters and actions use to save money by considering a few minor redesigns. It is especially true when we talk about catches and clips. Engineers often use them for assembling plastic components. Sometimes, design modifications, such as a part’ hole, helps in forming a catch without using lifters or actions. Experienced engineers with their vast knowledge in injection molding can produce high-quality mold designs and part designs with this technique.

Summary

So, we have learned about the working of auto-unscrewing mold and also talked about its aspects. The automatic unscrewing mold process is simple and straightforward. It is a highly economical and faster alternative to its manual unscrewing mold counterpart. Although many people still use the manual method, the automatic method is the approach that you should select to save time and extra labor costs. We also discussed injection molding undercuts and threaded plastic components that are relevant to our subject.

If you have more questions or queries regarding manual or automatic unscrewing mold, we are willing to help with our experts. Get in touch with us by clicking here. We always feel happy to provide our assistance.

Comparing Insert Mold and Traditional Mold

The industrial zone is full of techniques for molding different materials such that they fit with their specifications. The traditional way of molding was a revival for the mold-making industry. But now we have come way forward and are implementing as well as inventing new ways of molding.

The idea behind the technique of insert mold is to allow alterations and additions in the preexisting molded parts. Using the insert mold, a metal molded part inserts in a new mold. Then the plastic over-molding facilitates the partial or full coverage of the metal part.

Now, this is thermoplastic encasing of the metal component which is actually the mating of two parts to become the part of the bigger picture eventually.  Hence, the name insert mold comes into existence. More people are making the transition of using insert molding. This way they can develop a big product in parts, making the final assembly easier.

All you need to know about Insert Mold

The insert molding is the encapsulation of already molded parts in a thermoplastic. The ideal way of doing it is to give shape to molten plastic that is desirable in the final product. The traditional way of molding has many limitations therefore the insert mold technique is becoming an alternate solution.

Any particular project demands using different molds thus, the insert molding allows the molding of different parts despite their different characteristics and physical properties. Unlike insert molding, traditional molding demands to melt the plastic until they soften. This takes place at high temperatures.

Once the material reaches the desired physical state, it needs to fill the molds that have different shapes to achieve the final look. Consequently, it is a painstakingly long process and requires very precise steps. Although insert molding works on the basic principles of molding, it is still a laid-back technique with great results statistics.

Preferring insert mold over Traditional Mold

The insert molding process is viable as it makes use of melted resins and encloses the metal component. This process allows the plastic to encase the main metal body completely. Thus, the plastic outer body has no flaws with evenness in thickness. It even conceals the metal for any deformities due to earlier processing.

The varieties of applications associate with insert molding are countless. It even allows simple applications as well as complex ones. Majorly the reason to prefer insert mold over traditional mold is because of its continuity in production. By continuity, we mean that the plastic parts are in the form of a shield rather than add-on accessories.  Using mechanical bonding in insert molds, the plastic gloves the metal part just in a natural formation.

CNC Machining

CNC machining is the technique that allows this combination. It is good for providing soft grips and superior design. This is a sure short method of attaining sturdy structural designs that exude power and strength. One more reason to prefer insert molds over traditional mold is because of its cheaper production costs and further facilitates three-dimensional sculpting.

A traditional molding process is way more intense and involves too many steps. When using this process, the product has to go through injection, fusion, bonding, connectors, thread inserts, and fasteners. In short, there is too much going on. Unlike traditional molding, insert molding is precise and to the point. Moreover, the final product is much more consistent and sturdier. This gives the manufacturers a way better choice when they require molding.

Tip-Top Molds is all the facilities regarding molding. They provide services for all the molding processes under one roof.

Benefits of the using Insert molding process

As discussed earlier, the insert molding process is useful when we want parts that are strong and sturdy. It is by far the most reliable process for developing powerful tools. Moreover, it is very effective and has a high rate of efficacy when making molds for manufacturing processes. It makes up a consistent platform for making molds.

There are some major benefits of using the insert molding process for making molds.

Hand-Picked Material 

First of all, it lets the manufacturer choose the materials they want in the design mold. These materials are hand-picked due to their specialties. This means that the final product is compatible even before it comes into existence. Another reason for choosing specific materials is that they suit the production type whether it is marketable or domestic.

Affordable 

Moving on to the next benefit, insert molding is a cheap method for molding because of its cost-efficiency. The reason it is cost-effective majorly relies on the fact that it only consists of one step. This remarkably reduces the costs that might accumulate due to assembling and labor-intensive tasks in traditional molding processes.

Compatibility 

One more benefit of using insert molding is that all of the parts involved in the technique are already compatible. This means that there is no chance of failure or mishaps in alignment with the outcome. It substantially reduces the number of risks. The calculated results urge more manufacturers to invest in insert molding rather than other molding processes.

It even facilitates flexible design opportunities and allows the user to create unique components due to zero risks. The entire outcome is basically a single and even sheet of plastic thus the finishing is perfect. Some common examples include industrial tools, home-based utensils, chemical apparatus, and much more. It helps in catering to a vast variety of fields be it technical or domestic in nature. 

Summary

Finally, it is beneficial to conclude that the technique of insert molding is far more superior to any other technique used for molding. This is a state-of-the-art latest technology that manufacturers prefer over any other technique.

The reason it has been around for some time now is because of its long list of benefits that keep on increasing day by day. Moreover, it gives a chance to the manufacturers to experiment with different kinds of materials with zero risk factors. It emphasizes greater outcomes and lesser input whether it is related to labor, cost, or efficiency.  

A Guide to Overmolds Prototyping

In order to understand overmolds prototyping, it is better to get to know overmolds first. The process of overmolding involves the creation of one component. This single-component comes into existence using two or more than two materials that are unlike each other.

The first material for overmolds is a substrate that has a partial or full covering by the succeeding material in the manufacturing. This covering refers to the overmolding. In the manufacturing process, substrate and overmolding material play a major role in attaining the final product.

You can also refer overmolds as a molding process using an injection in combining different materials for making the wire and connector into a single component. Basically, one material overpowers the other one for this combination to exist. This article elaborates on the basics of overmolds for a comprehensive understanding.

The Use of Substrates in Overmolds Prototyping

As mentioned earlier overmolding prototype manufacturing includes substrates and overmolding materials. The first object or material inserted in overmolding is the substrate. In manufacturing terms, a substrate can be any material.

For example, it can be a metal component that came into existence using machined manufacturing or it can be in the form of a molded part consisting of plastic. It can even be a thread particle or a metal connector like screws and more.

The strategy behind making prototyping is to work on this very part known as the substrate. This very substrate will become a continuation in chemical bonding for goal attainment. It allows mechanical interlocking of different types of materials too.

Substrate, being the underlying layer serves as a platform. This becomes a solid foundation for further works required in overmolds prototyping. Moreover, this can be the beginning of a better way of molding objects as required.

The Use of Overmolding Material in Overmolds Prototyping

The next step of overmolds prototyping involves using an overmolding material. In most cases, the overmold material can be plastic. If it is plastic, then it comes in the shape of a capsule. For initiating the overmolds prototyping, it is important to add certain colors and fillers.

Sometimes it may need agents to create foam and make an even solution of the overmold material. The next step is to heat the capsulated overmold material until it reaches its molten point. Next, using an injection fill up the mold. This all takes place when the material is in the form of a liquid. There are some limits when using an overmolding material.

The most suitable material for the prototyping process is plastic. It is compatible with numerous amounts of materials. Otherwise, if you are using other materials then there might be some issues when covering the substrate.

Compatibility charts are often available with manufacturers that are into overmolding prototyping. It depends on the manufacturer and their experience with different materials. We, Tip-Top Molds (https://www.tiptopmolds.com) have vast experience in testing different types of material in overmold prototyping. You may select us due to our exceptional knowledge in combining materials for overmolds prototyping.

The Applications of Overmolds Prototyping

The industrial field requires many manufacturing procedures for their productions. Furthermore, overmolds prototyping is one of the many techniques used in the manufacturing of different components, for machinery or construction purposes.

The reason many companies are using overmolding prototyping is its ability in manufacturing different projects. Even if it does not produce the final product, it helps in producing the parts that are integral for the out-coming product.

Therefore, it has multiple applications compatibility in producing different types of materials. Some of the common household items come into existence after going through overmolding prototyping. This includes hand grips for our everyday appliances and objects like a toothbrush or a razor. The following are some more applications of overmolding prototyping.

Plastic over Plastic Overmolds Prototyping

As the name suggests, this kind of prototyping involves overmolding of plastic over and other plastic. A substrate is usually a solid form of plastic that needs molding. The next step is to surround the first plastic with another plastic.

The second plastic is in molten form so that it covers the substrate partially or completely as is the requirement by the manufacturer. Since the specifications of the final product depend on the client, the plastics used can differ in color, size, and other qualities.

Rubber over Plastic Overmolds Prototyping

Another application of overmolds prototyping is when making use of rubber over plastics. The first element or substrate is a slid kind of plastic. As usual, the substrate is in the molded form. Further, this plastic needs the covering of soft rubber or Thermoplastic elastomers.

We can experience this kind of coverage in products/devices with a gripping area that is soft. The soft area covers a solid part for easing the grip to facilitate proper handling.

Plastic over Metal Overmolds Prototyping

The next kind of prototyping involves using plastic and metal. In this case, the substrate is a metal that requires machining for its casting and formation. The next step is to insert the metal substrate into an injection. Over here, the injection acts as a tool for molding.

Then the manufacturers make use of plastic in molten form for giving coverage to the metal part. Once more, the metal is covered with plastic to provide a secure area for gripping. You can often locate this kind of prototype overmolding in screwdrivers, and more of these handy tools.

Summary

The technique of using overmold prototyping is becoming more and more common because of its cost variety of applications. Although it has some of its limitations, it is still a viable procedure for a variety of manufacturers. It allows using different kinds of materials. Moreover, you can even use different colored pigments and parts in achieving the desired result.

It is also an economical method for making physically and seamlessly bonded products. This allows the manufacturers to be more creative in productivity. It even adds flexibility along with a soft grip to different products.