This is incredible. this is stuff i've never hoped i would see free online . Thanks for shedding some light on how this large scale manufacturing is done
Using a valve to switch the flow is a whole lot faster than changing inserts, which means the long-term labor is a lot lower. Injection molding companies typically charge a setup fee each time you run a set of parts. That means the setup fee would be higher if they had to change the inserts.
Yes, you could just swap inserts to make the other version using a smaller mold base. However, you will need to remove the mold base from the injection molding machine to do the insert changeover. By adding the valve you negate the costly changeover time (and machine downtime) by spending a little more on a slightly larger mold base and added valve which allows the machine to make parts continuously for either design. In the end, the valve/larger mold base method is the more efficient and more profitable option.
Nice vid. Can I ask why you did not mill the mold yourself? You seem to have the equipment and expertise. Is it just something the injection molder wants to do themselves?
For several reasons. One is that this mold required the use not just of a mill, but also of an EDM machine (which I don't have). Another is that milling is just part of the work. The rest involves the placement of ejector pins, fitting the inserts into mold bases, etc. Also, it would take a lot of time. Since this was a project being paid for by another company, I was far more comfortable letting the experts make this mold.
@@JohnSL thanks for the insightful answer. i'm building a product right now, and your channel has been a massive help. the cost of injection molding is so daunting, and i always dream of being able to do it myself. but i realize now, maybe, there's no way around it
Thank you so much. Very informative. Are you going to use the mold on your Morgan press? Who is doing the mold? How much is the mold? Do you provide drawing services or mold services for a Morgan press?
Off Topic ut can you do metal injection molding with the same machine you are using for the plastic injection molding? And just add a couple of ovens for debinding and sintereing he green parts.
No, these were made by Texlon, who are also doing the injection molding. I covered this in some other videos. Here is one of them: th-cam.com/video/FQA5Efo9mBw/w-d-xo.html
I have rarely had that issue. The only time I've seen this happen is when the plastic stays in the cylinder at temperature for too long without injecting parts. This allows the heat to rise and soften the pellets at the time. When the machine is under normal use, the top is cooler, and you want to therefore have unmelted pellets at the top.
This is incredible. this is stuff i've never hoped i would see free online . Thanks for shedding some light on how this large scale manufacturing is done
Designing simplicity is not simple.
Well done. Getting the most out of a design.
Thank you for sharing these information!
Thanks for the video. One name for the round runner valves is “runner shut-off inserts”.
Thank you. Now I have the term I can use to find them.
@@JohnSL you can buy those from DME,DMS or from PCS. They also have CAD designs for all the mold components they sell.
Thanks for sharing. I don't understand the purpose of the valve. Couldn't you just swap the insert to make the other version?
Using a valve to switch the flow is a whole lot faster than changing inserts, which means the long-term labor is a lot lower. Injection molding companies typically charge a setup fee each time you run a set of parts. That means the setup fee would be higher if they had to change the inserts.
Yes, you could just swap inserts to make the other version using a smaller mold base. However, you will need to remove the mold base from the injection molding machine to do the insert changeover. By adding the valve you negate the costly changeover time (and machine downtime) by spending a little more on a slightly larger mold base and added valve which allows the machine to make parts continuously for either design. In the end, the valve/larger mold base method is the more efficient and more profitable option.
wow that was a huge mold, how much would that cost? ive heard molds of that size can be in the 5 figure range easily
were they made on your machines?
Could you provide me with a book course or any series of videos about plastic design and injection moulding ?
Nice vid. Can I ask why you did not mill the mold yourself? You seem to have the equipment and expertise. Is it just something the injection molder wants to do themselves?
For several reasons. One is that this mold required the use not just of a mill, but also of an EDM machine (which I don't have). Another is that milling is just part of the work. The rest involves the placement of ejector pins, fitting the inserts into mold bases, etc. Also, it would take a lot of time. Since this was a project being paid for by another company, I was far more comfortable letting the experts make this mold.
@@JohnSL thanks for the insightful answer. i'm building a product right now, and your channel has been a massive help. the cost of injection molding is so daunting, and i always dream of being able to do it myself. but i realize now, maybe, there's no way around it
Was there any Ideation & mockup phase for the form? or did you just model it in Fusion straight?
Thank you so much. Very informative. Are you going to use the mold on your Morgan press? Who is doing the mold? How much is the mold?
Do you provide drawing services or mold services for a Morgan press?
This is way too large for my Morgan. The molds were made and all the injection molding is being done at Texlon Plastics in Gastonia, NC.
Off Topic ut can you do metal injection molding with the same machine you are using for the plastic injection molding? And just add a couple of ovens for debinding and sintereing he green parts.
I've heard of MIM but never learned enough about it to know how it works.
Did you mill the molds yourself?
No, these were made by Texlon, who are also doing the injection molding. I covered this in some other videos. Here is one of them: th-cam.com/video/FQA5Efo9mBw/w-d-xo.html
Hi John I have a quick question to ask about your machines how do you stop the plastic sticking to the plunger any help would be great
I have rarely had that issue. The only time I've seen this happen is when the plastic stays in the cylinder at temperature for too long without injecting parts. This allows the heat to rise and soften the pellets at the time. When the machine is under normal use, the top is cooler, and you want to therefore have unmelted pellets at the top.
I can't tell you how many TCS decoders I have installed but it is alot.
yay