Rapid prototyping technology and development

Rapid Prototyping (RP) technology, also known as rapid prototyping technology, is one of the rapidly developing manufacturing technologies in the world today. Rapid prototyping technology is a computer-controlled, based on the principle of discrete, stacked with different methods of accumulation of materials, and ultimately complete the parts of the forming and manufacturing technology.

1, from the forming point of view, the parts can be regarded as "point" or "surface" superposition. The geometrical information of "point" or "face" is discretized from the CAD electronic model, and then combined with the information of the forming process parameters, the material is regulated to accumulate the parts from point to surface and from surface to surface.

2, from the manufacturing point of view, it is based on CAD modeling to generate parts of the three-dimensional geometric information, control multi-dimensional system, by laser beam or other methods of material layer by layer to form a prototype or parts.

The main features of RP technology are:

1, rapid RP manufacturing technology is the concurrent engineering of complex prototyping or parts manufacturing an effective means to enable product design and mold production simultaneously, thereby enhancing R & D efficiency, shorten the product design cycle, greatly reducing the cost of new product development And risk, for the smaller size, shaped products are particularly applicable.

2, CAD / CAM technology integration Design and manufacture of integration has been a difficult point, computer-aided process (CAPP) at this stage because it can not and CAD, CAM completely seamless docking, which is restricting the manufacturing information And rapid prototyping technology integrated CAD, CAM, laser technology, numerical control technology, chemical engineering, material engineering and many other technologies, making the concept of design and manufacturing integration to achieve a perfect one.

3, complete reproduction of three-dimensional data through rapid prototyping and manufacturing of complete parts, complete true reproduction of three-dimensional modeling, regardless of the outer surface of the contour or the cavity of the shaped hole, can be true and accurate completion of modeling, basically no longer need to help External devices to repair.

4, a wide range of molding materials So far, all kinds of RP equipment used in a variety of materials, resin, nylon, plastic, paraffin, paper and metal or ceramic powder, basically meet the vast majority of products on the material Mechanical performance requirements.

5, to create significant economic benefits Compared with the traditional mechanical processing, development costs to save more than 10 times, the same rapid prototyping technology to shorten the enterprise product development cycle, so that in the new product development process of repeated revisions to the design of the program greatly Reduce, and basically eliminate the problem of modifying the mold, to create economic benefits is obvious.

6, the application of industry-wide RP technology After years of development, technically has basically formed a system, the same can be applied to the industry has gradually expanded, from product design to mold design and manufacturing, materials engineering, medical research, Culture and art, construction, etc. are gradually using the RP technology, making RP technology has broad prospects.

Direction of development

From the current RP technology research and application status, rapid prototyping technology for further research and development work mainly in the following areas:

(1) the development of good performance rapid prototyping materials, such as low cost, easy to shape, small deformation, high strength, durable and pollution-free forming material.

(2) to improve the processing speed RP system and open up the manufacturing process of parallel methods.

(3) to improve the reliability of the rapid prototyping system to improve its productivity and the ability to produce large pieces of equipment to optimize the structure, especially to improve the accuracy of forming parts, surface quality, mechanical and physical properties, for further mold processing and functional experiments provide the basis .

 (4) the development of rapid prototyping of high-performance RPM software. Improve the speed and accuracy of data processing, research and development using CAD raw data direct slicing method to reduce the STL format conversion and slicing process generated by the loss of accuracy.

(5) the development of new forming energy.

6) rapid prototyping method and process improvement and innovation. Direct metal forming technology will become the future research and application of another hot spot.

(7) rapid prototyping technology and CAD, CAE, RT, CAPP, CAM and high precision automatic measurement, reverse engineering integration research.

(8) to improve network services research efforts to achieve remote control.

transparent plastic products in medical application

As the plastic has a lightweight, good toughness, easy molding. Low cost, so in modern and daily products, more and more use of plastic instead of glass, especially for optical instruments and medical aspects, the development is particularly rapid. However, due to the requirements of its transparency is better, high wear resistance, impact toughness is better, so the composition of the plastic, the entire process of injection molding equipment. Mold, etc., have to make a lot of work to ensure that the plastic used to replace the glass, the surface quality is good, to achieve the requirements.

Transparent plastic must first have a high degree of transparency, followed by a certain degree of strength and wear resistance, to impact, heat resistance is better, chemical resistance is excellent, water absorption is small, only to use, to meet the transparency requirements and long-term deformation

This is the main properties of plastic products

Injection molding process characteristics of three kinds of commonly used transparent plastics

1, PMMA

The viscosity of PMMA is large, the fluidity is little, so it must be high temperature and high injection pressure. The injection pressure is helpful to improve the shrinkage of the product.

The injection temperature range is wide, the melting temperature is 160 DEG C, the decomposition temperature is up to 270 DEG C, so the material temperature adjustment range is wide, and the process is better. Therefore, improve liquidity, from the injection temperature.

2, PC

PC viscosity, melting temperature is high, poor liquidity must be at higher temperature injection (270~320 DEG C), relatively speaking, the temperature range is narrow, the process is not as good as PMMA.

Injection pressure has little effect on the fluidity, but because of the high viscosity, the injection pressure is still larger. To prevent internal stress, the holding time should be as short as possible.

High shrinkage rate, stable size, but the product of large internal stress, easy to crack, so should be used instead of increasing the temperature pressure to improve the liquidity, and by increasing the mold temperature, improve the mold structure and postprocessing to reduce the possible cracking.

3, PET

PET molding temperature is high, the material temperature adjustment range is narrow (260 - 300 DEG C), but after melting, the fluidity is good, therefore the craft is poor, and often in the nozzle to be added to prevent the flow device.

The mechanical strength and performance of the injection is not high, must be through the stretching process and modification to improve performance.

The accurate control of mold temperature is an important factor to prevent warpage.

At the same time transparent plastic products, easy to produce blooming

Blister Mold material selection

1, the choice of blister c mold

Blister mold generally have plaster mold, copper mold and aluminum mold

Gypsum mold: plaster molding in the semi-wet state, and then drying mold, plaster mold low cost, easy to modify, but the plaster mold precision is not high enough, the surface is not smooth and fragile is not durable, so it is often used to fight To do the electroplating of copper mold or some of the requirements of small-batch production of plastic mold.

Aluminum mold: with aluminum ingots through the machinery (lathes, milling machines, CNC, etc.) from processing.

Aluminum mold high precision, smooth surface and durable, but the price is very expensive, aluminum mold is generally used in high precision copper mold not reach the blister products.

Electroplated copper mold: Plaster mold made of samples, the plating layer of copper shell is the electroplating copper mold, the cost of relatively high plaster mold, but much cheaper than aluminum mold, because of its smooth and durable surface, low cost, electroplating Copper mold is the most commonly used a plastic mold.

2， the choice of plastic material

Blister packaging products include: bubble shells, trays, plastic boxes, as well as: vacuum cover, blister, and so on.

Blister products are only plastic sheet material, film thickness is generally not more than 1.5MM, commonly used sheet: PVC, PET, PP, PS and on this basis, flocking sheet, gold-plated sheet and anti-static sheet .

PVC: the most commonly used plastic material, soft, toughness, good plasticity, can be made transparent and a variety of colors, commonly used transparent PVC packaging electronics, cosmetics, toys, gifts and other products.

PET (A-PET): hard, good toughness, high strength, bright surface, environmentally friendly non-toxic, transparent and a variety of colors of the sheet. Disadvantages of PET high-frequency heat more difficult, the price is much more expensive than PVC, this material is often required to replace high-end and environmentally friendly products, PVC

PS: small density (light), environmental non-toxic, plasticity is very good, toughness is not easy to brittle, can not be made of transparent material, it can only be made at the end of care plastic, because of its easy to crack,

PP: material is particularly soft, tough, environmentally friendly non-toxic, high temperature, often made of food containers or other high temperature packaging products; but its poor plasticity, processing difficulties, poor surface gloss, and the processing of color change shallow.

PET-G: physical properties with the A-PET almost, but high-frequency heat, the price is more expensive than A-PET 80%

3, The determinants of price of plastic products

Blister = unit material cost of materials + energy + labor + transport + profits

Energy consumption: Blister is through the thermal processing, power consumption relative to other industries larger, roughly for the material cost of 8%

Artificial: Blister mainly by machine production, less artificial, roughly 10% of the cost of materials,

Transportation: According to the customer from the factory and distance,

Profit: Plastic factory net profit is generally low, 12% -20%, depending on the payment period, 30 days checkout is 14%

Material cost: The material cost of the product is relatively complicated. Before the calculation, the following data should be clarified:

Raw material price: according to the use of the product, to determine what kind of material and grade of material, to find the lowest price of this material suppliers

Film Thickness: Extending The product must be made of thick film, according to the shape of the thickness and shape of the various parts of the

The number of typesetting: according to the size and shape of the product, the number of molds can be calculated in a version, the density will reduce the quality of products, thinning will increase the material loss, so that the cost of material loss rate: the main factor is the product shape, The number and size of the chassis fit with the degree of plastic, the shape of the more Founder, the greater the output, the smaller the loss rate

In addition to blister mold, we are also good at injection mould  and injection molding.

Now Plastic Manufacturing on the Rise in China

The world of plastic products manufacturing has come a long way since the 1860s — and rapidly growing companies like CN-MOULDING are proof. While John Wesley Hyatt may not have realized it when he first experimented with cellulose nitrate in the late 1800s, the substance he discovered has since become a major part of everyday life in the China.

“Today’s plastics are one of the most used materials on a volume basis in China. industrial and commercial life,” says PlasticsIndustry.org. “(They are) broadly integrated into today’s lifestyle and make a major, irreplaceable contribution to virtually all product areas.”

The two main types of plastics are thermoplastics and thermosets, the first of which is used to create many of the most common industrial, consumer and commercial products on the market today. What turns the plastic into a useful product is a process called injection molding, a high-production process originally launched in the late 1940s by American inventor James Watson Hendry.

Here’s how injection molding works: manufacturers inject the thermoplastic into a mold where it can set and form into the size and shape desired. While the process is fairly simple in concept, it offers a wide range of advantages, like higher production rates, lowered labor costs and reduced waste. And today’s businesses are increasingly moving their injection molding back to the China, to companies like CN-MOULDING, to experience further benefits like lowered freight costs, faster turnaround times, easier face-to-face meetings and quicker access to inventory. Choosing to do plastic products manufacturing within the China. means freed-up resources, lower lag times, and more convenience when making product adjustments or changes.

“CN-MOULDING plastic products manufacturing provides all kinds of benefits to world companies,” said Kenny Han, a vice president at CN-MOULDING. “It’s much simpler to communicate, make changes, view samples and so on — not to mention cheaper and more efficient in the process.”

This increasing push for onshoring shows that China plastic products manufacturing is booming — and there are other evidences in place, too. Injection molding and 3D printing is a hot trend in the plastics industry today, being used for everything from military equipment to medical devices. Network World says 3D printing is “the hottest new technology on the IT landscape,” offering further proof that China plastic manufacturing continues to grow.

Plastic Injection Molding Manufacturer CNMOULDING Benefits Clients by Cutting Sales Costs

By taking advantage of Internet, CNMOULDING gets the edge in supplying the most cost-effective plastic injection molding products to customers from all over the world. Now CNMOULDING is providing an array of first-class products and services in automotive, home appliances and electronics

SHANGHAI, China, August 30, 2015  -- Plastic injection molding products has been widely used in many industries and CNMOULDING promises customers direct benefits through its easy and definitive consumer approach module. The company's objective to become the "one stop shop" is facilitated through its 2000 sq meters workshop in China.  Powered by world-class infrastructure, a large and adroit workforce and a solid management team, the company has become a trusted supplier of plastic molds for many European and North American based companies. Furthermore, CNMOULDING claims to be the only China plastic molding injection company that offers complete cost analysis and full transparency to prospective buyers.

Company insiders indicate that the biggest plus of working with CNMOULDING is in the direct method of approach that the company adopts. As a top plastic injection molding manufacturer, CNMOULDING has earned its fame though innovation, quality control and cost-down.  According to their reports, CNMOULDING picks up direct consumer leads from the Internet and then tries to establish direct contact. Company officials have also, on several occasions, shown why the conventional way of marketing through trade shows is becoming obsolete. The company plans further expansion and the owners indicated that they are bringing more innovation in the manufacturing process to accelerate production and reduce downtime.

CNMOULDING has also made an elaborate effort to keep their price structure transparent for their international clients. While most similar companies would make every effort to conceal the numbers, CNMOULDING promises to give their clients a sneak peek into the pricing and profit structure.

The managerof CNMOULDING recently addressed the local press. He laid great emphasis on the sales team of the company: "Most companies tend to carry out their sales through salespersons who exhibit an acute lack of product knowledge. At CNMOULDING, our sales manager deals with all the sales and effectively communicates the messages in and out of the company. We also make it a point to adhere to transparent pricing."

About the company

CNMOULDING is a leading direct plasticinjection company based out of China. The company caters to both the Chinese and international markets.

More information about the company is available at www.chinamoldmaker.org   

Injection mold Features

① core cavity and a three-dimensional profile. External and internal shape of plastic parts by direct molding cavity and core of these complex three-dimensional surface machining more difficult, especially within the cavity molding surface machining blind hole, if the traditional processing methods, not only requiring high skill level of workers, auxiliary fixtures more tools and more, and a long processing period.

② accuracy and surface quality requirements, long service life requirements. Currently dimensional accuracy requirements are generally plastic parts for 1T6? 1T7, dimensional precision surface roughness Ra0.2-0.1um injection mold parts required to achieve 1T5? 1T6, surface roughness Ra0.1um less. Long-life plastic injection mold for mention Gao efficiency and reduce costs necessary to present the life of the injection mold generally require more than one million times. Precision injection molding to use the stiffness of the mold. Increase the thickness of the template Increasing support column or cone positioning

Element to prevent deformation of the mold under pressure, internal pressure can sometimes reach lOOMPa. Top of the device is an important factor affecting the product deformation and dimensional accuracy, so you should choose the best top of the point to make uniform throughout the release. Precision injection molds most used in the structure or spelling mosaic structure, which requires precision mold parts interchangeability are greatly improved.

③ long process, the manufacturing time is tight. For injection molded parts, mostly with other components to form a complete package of products, and in many cases are in other parts have been completed, the eagerly awaiting public on supporting injection molded parts. Because of the product's shape or size of high precision, combined due to the characteristics of the resin material is different, after the completion of mold manufacturing, also requires repeated tryout and revision, enabling developers and delivery time is very tight.

④ remote design, remote manufacturing. Mold manufacturing is not the ultimate goal, but to present the final product design, mold making factory according to user requirements design and manufacture molds by the user, and in most cases, the products of other manufacturers also produce injection. This situation resulted in the design, mold design and manufacture products, production of products carried out in different places.

⑤ specialization, dynamic combination. Mold production volume is small, generally belong to a single piece of production, but the mold needs a lot of standard parts, large mold, small thimble, these should not and can not just be done by a single manufacturer, and manufacturing process complexity, general equipment and CNC devices use very uneven.

more information www.chinamoldmaker.org 

http://cnmoulding.tumblr.com/post/125560705428/injection-molding-design-issues-should-be-noted

The mold impact of injection molding production

 

Mold because it can duplicate the production structure and shape of complex products, but also has high production efficiency, part shape, and uniform size, high precision parts, bulk and low cost, so the mold has become a manufacturing cost-efficient production of important technical support, a national mold industry level has become an important measure of the level of its manufacturing standards. Meanwhile, the main factors affecting the quality of the mold is product quality.

 

Injection mold injection product processing is the most important molding equipment, its quality is directly related to the merits of product quality. Moreover, since a large proportion of injection molding mold occupy in production costs, which is about the life of a direct injection product's cost. Therefore, improving the quality of injection molds, and maintenance and repair, extended its life cycle, are injection molding production cost reduction and efficiency an important issue. Meanwhile, the mold structure for injection molding equipment and raw material costs are also closely linked.

 

Second, the impact of injection mold production

 

Injection molds for injection molding have a huge impact mainly reflected in the following aspects

 

1. Select the injection molding machine for injection molding machines and die because of limitations related parameters, a type of injection molding machine die size allows installation there is a certain range, that is when mold making good, the corresponding minimum machine it has been determined. This ensures that companies supporting the injection molding machine, otherwise, it is possible to increase the injection molding machine models will inevitably result in the waste of the machine.

 

2. Requirements of the mold temperature requirements of the injection facilities may require mold temperature water connector specification, the number of groups waterway wire connection method

 

Requirements 3. Injection environmental impact of the product because the material, accuracy requirements, maybe required injection ambient temperature and humidity

 

4. Product quality and product quality is at least 70% of the factors in the mold, for high-precision injection molding machine, mold influence more prominent. For the appearance of the product surface, surface striae mainly to see the effect of the mold, glossy, mirror, etc. mainly to see the quality of the mold cavity surface polishing. For products of non-appearance of the surface, the mold surface quality can be directly reflected in the surface roughness of the product for the product dimensions, in addition to affecting the product shrinkage and the injection molding process, the most direct impact is mold dimensional accuracy. The higher precision Die size, dimensional accuracy is also higher. Produce many other plastic product defects, mold factor occupies a large proportion. See the narrative below.

 

5. molding cycle mold design, for gate location, etc waterway layout will affect the production of the injection molding cycle. Short molding cycle, direct injection to enhance production efficiency and capacity of injection molding machines, but also means lower production costs.

 

6. Raw Material - production costs (waste) design mold runner system will affect the injection of waste generated in a gram weight, these wastes actually increase the cost of production.

 

7. The degree of automation of production mold design, injection molding automation need to be considered to achieve, such as the top of the well, no post-processing, production of stable quality and risk-free. If the mold can not meet the requirements, it must have an operator for the production, which is bound to increase in labor costs, and increase the instability of product quality.

 

8. After processing reasonable mold design, product to meet the requirements, there is no need for post-processing, such as repair flash, cut the gate, orthopedic, all seized