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.

Injectionmould tooling

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:

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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.

Jul 13, 2016 — Aluminum is soft by nature and can be difficult to work with. In fact, it may form a gummy buildup when cut or machined. This is because ...

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Injectionmouldtool design

Most CNC lathes have Constant Surface Speed (CSS) to counteract the natural decrease in surface speed. This speeds up the spindle as the tool moves closer to the turning axis. By utilizing CSS the lathe is adjusting the revolutions per minute to maintain a constant surface speed at every distance from the center.

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Plastictooling

Cutting speed is the speed that the material moves past the cutting edge of the tool. Cut speed can be defined as revolutions per minute (RPM) or as surface feet per minute (SFM).

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.

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.

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At Martin, we pride ourselves on understanding feeds and speeds and optimizing them for our customers. Our Metalworking Team is ready to share their expertise and find custom-tailored solutions that fit your needs. To learn more about how we can help you maximize the profitability of your machine shop, contact your Martin Sales Rep or call 800.828.8116.

Revolutions Per Minute (RPM) relates directly to the speed, or velocity, of the spindle. It represents the number of turns completed in one minute around a fixed axis. RPM maintains the same revolutions per minute throughout the entire operation.

For example, if two round pieces of different sizes are turning at the same revolutions per minute, the larger piece will have a greater surface speed because it has a larger circumference and has more surface area. As the tool gets further into a workpiece, the same spindle speed will produce a decreasing surface speed. This is because each revolution represents a smaller circumferential distance, but takes the same amount of time.

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Surface Feet Per Minute (SFM) is a combination of the cut diameter and RPM. The faster the spindle turns, and/or the larger the part diameter, the higher the SFM.

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.

Mould toolingmachine

Cutting tool manufacturers publish the general feeds and speeds and recommended usage for the application. That is often a good place to start for recommendations on tool selection and feeds/speeds, but best practice is to work directly with a cutting tool expert at your machine.

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.

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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By signing up, you agree to our Terms of Use and Privacy Policy. We may use the info you submit to contact you and use data from third parties to personalize your experience.

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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.

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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.

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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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.

Mould toolingcost

Through Martin’s Tool Analysis Program, companies can find ways to improve their processes and make sure they’re getting the most out of their products.

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So what is HEM and why should you care about it? Wait, what about HSM? HSM, or High Speed Machining has been around for many years in various ...

Injection moldingtoolingcost

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Injection moulding process step by step

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Feed rate is the velocity at which the cutter is advanced along the work-piece. Feed rate is expressed as units of distance (inch) per minute or per single revolution.

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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.

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.

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Feeds and speeds refer to two separate velocities for machine tools: feed rate and cutting speed. They are often considered as a pair because of their combined effect on the cutting process.

Materials will run better at specific SFMs. SFM is a constant, with RPM as a variable based upon cut diameter.  When the SFM constant is known for a specific material, the formulas below can be used to determine spindle speed:

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CNC machining is the backbone of many manufacturers’ processes. Unfortunately, they are also a major cost center and can be a bottleneck when it comes to getting the product quickly through the plant. Far too often we find that a company has invested in quality inserts and tooling, but is not running them at the proper feeds and speeds.

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