Injection moulding process step by step

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Such molds enable our customers to save on NRE costs at the beginning stages of a new product, and help bring an initial product to market faster. This can unlock investments and produce a bridge production quantity of parts to tide them over until production tooling comes online.

Mould toolingcost

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During these validation phases, more than one third of Fictiv customers’ tools require design changes through an ECO, which usually takes 3-5 days to modify the tooling. Single cavity, P20 or NAK80 tooling for ECO’s provides more freedom to make non steel-safe changes than aluminum at a lower cost than a hardened steel, multi-cavity production tool.

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Mould toolingmachine

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There are multiple commonly used grades of metals for tooling, and they’re typically used for the different stages of product development and validation. These different types of materials produce molds that provide assorted achievable tooling lead times and costs, different plastic part cycle times and associated unit costs, and varying levels of dimensional part precision and cosmetic quality of appearance.

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Usually, Fictiv customers start with single cavity, P20 or NAK80 steel tools for their engineering validation testing (EVT) and design validation testing (DVT). These tools are finished and produce the first samples (T1) in 10-25 days.

Injectionmouldtool design

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Injection tool name

According to the legend, Athena, who had invented the flute, threw it away in disgust, because it distorted the features.

Oftentimes engineers and product designers place much focus on selecting the appropriate grade of plastic when developing injection molding part designs. Equally important, though frequently an afterthought, are the metal materials used to manufacture the injection molding tool itself.

Plastictooling

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A word of advice: we find that if customers 3d print a prototype set prior to releasing tooling, the need for ECO’s is drastically reduced.

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Injection moldingtoolingcost

Each type of mold material has its advantages and disadvantages, so it helps to create a “game plan” early in the design process for tooling and bringing your product to market. Here, we’ll discuss the prevalent mold materials, their advantages and disadvantages, and common use cases for each.

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Though the sequence described above is typical for Fictiv customers, there are factors which may prompt engineers and product designers to do it differently. Fictiv has a wealth of knowledge and expertise for injection molding, both in the US and overseas, and we’re happy to review and provide DFM feedback on your next tooling project.

Aluminum is often used as an alternative to harder steel grades in situations that call for faster tool production time and prototype/low volume part production. Though aluminum is a common material in the industry, at present, it’s seldom used by Fictiv.

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Middle English floute from Old French flaute from Old Provençal flaüt perhaps a blend of flaujol flageolet (from Vulgar Latin flābeolum flageolet) laut lute lute1

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If the product demand is high and the designs are finalized and locked, customers typically move to hardened steel, production multi-cavity tooling. The NRE tooling costs are higher, but the minimized unit pricing and cycle times combined with maximized production capacity make it a logical next step in tooling.

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NAK80 is semi-hardened tool steel, which Fictiv most often uses for highly polished clear or glossy plastic parts. It’s also used when the tooling life needs to be longer than P20 steel or when a part has several side actions. It has similar advantages and disadvantages as P20, plus:

This grade of steel is the most commonly used for high production quantity tooling, and is good for thermal fatigue, and longer tooling life. It can better resist wear from some plastic materials, such as those with glass-filled additives, than the metal materials previously listed.

Hardened steels are most often used for high production quantity tooling. They’re typically multiple cavities with hot runner systems. The tool lives are longer but the manufacturing time and tooling costs are the highest of any material. High production quantity tooling is used to minimize part unit costs, which offsets the higher up front NRE (non-recurring engineering) costs.

Injectionmould tooling

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P20 is a commonly used, general purpose tool material. It strikes a strong balance between cost, available tooling lead time, part quality and dimensional part stability. Fictiv often uses another grade of steel, 718H, which is a bit harder than P20, but has the same general advantages and disadvantages.

We exist to eliminate bottlenecks in new product development by integrating the people, processes, and platform you need to source custom parts.

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