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Injection Molding Review | Injection Molding Design Guide
Continued from Injection Molding Equipment & Machines
Injection Molding Molds and Tooling: Mold or die are the common terms used to describe the tooling used to produce plastic parts in molding.
Traditionally, molds have been expensive to manufacture. They were usually only used in mass production where thousands of parts were being produced. Molds are typically constructed from hardened steel, pre-hardened steel, aluminum, and/or beryllium-copper alloy. The choice of material to build a mold from is primarily one of economics, steel molds generally cost more to construct, but their longer life span will offset the higher initial cost over a higher number of parts made before wearing out. Pre-hardened steel molds are less wear resistant and are used for lower volume requirements or larger components. The steel hardness is typically 38-45 on the Rockwell-C scale. Hardened steel molds are heat treated after machining. These are by far the superior in terms of wear resistance and life span.
Typical hardness ranges between 50 and 60 Rockwell-C (HRC). Aluminum molds can cost substantially less, and when designed and machined with modern computerized equipment, can be economical for molding tens or even hundreds of thousands of parts. Beryllium copper is used in areas of the mold which require fast heat removal or areas that see the most shear heat generated. The molds can be manufactured by either CNC machining or by using Electrical Discharge Machining processes
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