Die casting mold design is a technique for mass-producing metal products and components. Mold design is one of the most important steps in the process because the shape and attributes of the mold will directly affect the final product. The die casting procedure forces molten metal into molds using high pressure and it requires a mold with exact specifications to achieve the task.

There is something very important for the die casting mold design, these key points will influence the die casting die manufacturing successfully or not,  during the die casting injection mold design phase, please consider 8 key points as below.

• Die draft angle
• Fillets on mold & part
• Casting die Parting lines
• Casting Part Bosses
• Part Ribs
• Holes and windows on Part
• Symbols
• Wall thickness of Part

Draft

The draft is the degree to which a mold core can be tapered. A precise draft is needed to smoothly eject the casting from the die, but since the draft is not constant and varies according to the angle of the wall, features such as the type of molten alloy used, shape of the wall, and depth of the mold can affect the process. Mold geometry can also influence draft. In general, untapped holes require tapering, due to the risk of shrinkage. Likewise, inner walls can also shrink, and therefore require more drafting than outer walls. you can search draft angle for more information on the die casting mold design and manufacturing.

Fillets

A fillet is a concave junction used to smooth an angled surface. Sharp corners can hinder the casting process, so many molds have fillets to create rounded edges and reduce the risk of production errors. With the exception of the parting line, fillets can be added nearly anywhere on a mold.

Parting Line

The parting line, or parting surface, connect different sections of the mold together. If the parting line is imprecisely positioned or becomes deformed from work strain, material may seep through the gap between the mold pieces, leading to non-uniform molding and excessive seaming.

Bosses

Bosses are die cast knobs that serve as mounting points or stand-offs in mold design. Manufacturers often add a hole to the interior structure of the boss to ensure uniform wall thickness in a molded product.  Metal tends to have difficulty filling deep bosses, so filleting and ribbing may be necessary to alleviate this problem.

Ribs

Die-cast ribs can be used to improve material strength in products lacking the wall thickness required for certain applications. Selective rib placement can reduce the chance of stress cracking and non-uniform thickness. It is also beneficial for decreasing product weight and improving fill capabilities.

Holes and Windows

Including holes or windows in a die-cast mold directly affects the ease of ejecting a completed molding and enables the creation of substantial drafts. Additional features, such as overflows, flashovers, and cross feeders may be necessary to prevent unwanted casting within the holes or poor material flow around the holes.

Cooling system

The die casting mold cooling system is different to the plastic injection mold that must be without “o” design because of the mold temperature will be more than 2 hundred degrees and the mold must increase to hot before the casting production. the conformal cooling system is best for the casting part quality and cycle time.

Symbols

Manufacturers often include brand names or product logos in the mold design of die-cast products. While symbols do not typically complicate the die casting process, their use can affect production costs. In particular, a raised logo or symbol requires additional molten metal volume for each manufactured part. Conversely, a recessed symbol requires less raw material and can reduce expenses.

However, How to design a quality die casting mold that is a professional and comprehensive working, it bases on the designer’s design skill, die casting manufacturing and casting experience.

UPMOLD is a Custom manufacturer of molds with +/-0.0002 in. tolerance. ABS, acetal, acrylic, Delrin®, nylon, phenolic, polycarbonate, polypropylene, polyethylene, polystyrene, polyurethane and Ultem® materials worked. Capabilities include blow molding, die molding, hot pressing, injection molding, overmolding, tooling, assembly, welding, machining, milling and turning. Aerospace, optical, agricultural, automotive, electronics, marine, medical, military, pharmaceutical and other industries served. Meets AS 9100, ASTM and SAE standards. ITAR registered.

Injection Plastic Mold Design solutions for elbow plastic parts such as below pictures shown

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The Injection Mold Design with 4 sliders what are 2 rotating sliders and line sliders with hydraulic driving, combining with link mechanism and gear mechanism.

Injection Molding Mold Design construct:

Sliders: 4

Slider driving: Angle pin, hydraulic cylinder,

Mechanism: Gear mechanism

Injection Mold Design construct:

Sliders: 6

Slider type: 4 line sliders & 2 rotating sliders

Slider driving: 3 sliders with Angle pin, 1 by the hydraulic cylinder and others with link mechanisms

Mechanism: Slider-crank mechanism

This is a Rearview mirror housing injection mold design solution,

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Injection Molding Mold Design construct:

Sliders: 4

Lifters: 2

Slide in slide.

Injection Molding Mold Design construct:

Sliders: 2

2 slides composite application

Injection Molding Mold Design construct:

This is a T branch injection mold design for injection molding mold custom.

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Injection Molding Mold Design construct:

Sliders: 4

Slider type: 3 line sliders & 1 rotating sliders

Slider driving: Angle pin & Rack with hydraulic cylinder

Mechanism: Gear Mechanism

Injection Molding Mold Design construct:

Sliders: 3

Slider type: 2 line sliders & 1 rotating sliders

Slider driving: Angle Pin & Hydraulic Cylinder

Mechanism: Slider-crank mechanism

Injection Molding Mold Design construct:

Sliders: 2

Slider type: 1 line sliders & 2 rotating sliders

Slider driving: Rack with Hydraulic Cylinder

Mechanism: Gear mechanism

Terms: 40% down, 30% after 1st sample or shipment, 30% Net 30 on approval
F.O.B. Shenzheng

Reference:1 New 2 Prototype 3 Budgetary 4 Components

injection mold price Form: 1 3D Geometry 2 Sample Part 3 Part Print/2D Drawing 4 JPG/Sketch 5 Other

injection mold price: 1 Build Only 2 Design Only 3 Design and Build

Cavitation

Steel:1 P-20(28-32RC) cavity&core solid 2 P-20(28-32RC)cavity&core inserts 3 Stainless steel pre-hard(24-32RC) 3 S-7 Steel(54-58RC)cavity&core inserts 5 H-13(48-52RC)cavity&core inserts 6 Other

Mold Base: 1 DME Std.construction(English) 2 DME Std.construction(Metric) 3 Other

Inserts: 1 Inserts per cavity 2

locks:straight Lock Side Mount 2 Straight Lock Top Mount 3 Intergral Part Line Lock 4 Other

Gating: Cold Sprue surface runner 2 Hot Sprue into cold runner 3 Hot Sprue pinpoint gated 4 Sprue gated direct into part 5 3-plate gated 6 pinpoint gated 6 Hot Manifold

Ejection:1 standard ejector pin guided under motion 2 standard ejector pin NOT gueded under motion 3 stripper plate ejection 4 stripper ejection 5 lifter ejection 6 sleeve ejection 7 Ejetor blade ejection 8 Ejecor system spring returned 9 Tapped PKO’s 10 parting line Bar lifters 11 Hydraulic ejection
1.Quote includes 3 trial, 30 shots per sampling.
2.Marking is required.
3.All standard parts need to be used with equivalent standard.
4.Mold Base :all plates are 1050.

There are many complicated solutions for Injection Mold design, as below pictures shown

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In this mold design concept, you will obtain how to combine the complicated mold sliders and control the slider moving step by step.

Plastic Mold Design Description:

Sliders: 4

Slider type: 3 line sliders & 1 rotating slider

Slider driving: 3 sliders with Angle pin, 1 by the hydraulic cylinder

Mechanism: Slider-crank mechanism

This mold design concept for the undercut at core inside of the injected part.

Plastic Injection Mold Design Description:

Sliders: 2

Slider type: line slider

Injecting part ejection out from slider with lifers for injection molding mold.

Mold Design Description:

Sliders: 5

Lifters: 2

There are many solutions for elbow injection mold design, as below pictures shown

Cause the GIF image files are big, Please wait for a moment.

Injection Molding Mold Design construct:

Sliders: 4

Slider type: 2 line sliders & 2 rotating sliders

Slider driving: Rotary & Guide Path Block

Mechanism: Gear Mechanism

Injection Molding Mold Design construct:

Sliders: 3

Slider type: 2 line sliders & 1 rotating sliders

Slider driving: Angle Pin & Hydraulic Cylinder

Mechanism: Slider-crank mechanism

Injection Molding Mold Design construct:

Sliders: 18

Slider type: 16 line sliders & 2 rotating sliders

Slider driving: Angle Pin, Rack & Hydraulic Cylinder

Mechanism: Slider-crank mechanism

Plastic Injection Resin application Sheet that is a reference to our colleague how to plan the material necessary for injection molding mold trail, this sheet design base on cost-controllable, reasonable and savable to provide our customer good communication and service.

Injection molding custom manufacturer UP MOLD Offering:

• Plastic over-molding mold
• Double color injection mold
• Plastic injection molding
• Insert molding
• Multi-cavity mold
• Single cavity mold & products
• Family mold tooling & products
• Hot runner mold tooling & products
• Tooling assembly and product assembly
• Secondary Operations
• Rapid prototyping tooling & product production