Forget typical cycle times. We’re pushing the boundaries of conformal cooling.  While traditional approaches deliver reductions, at SyBridge, we see further.  By combining our expertise in 3D printing, mold tooling design, and in-house manufacturing, we engineer conformal cooling solutions that unlock the true potential of this transformative technology. Our unique synergy allows us to not just achieve impressive results, but to truly test the limits of what conformal cooling can accomplish for your product.   

Conformal cooling improves throughput 

SyBridge uses conformal cooling designs–either in retrofitting older tooling or as an initial design element–to enhance cooling efficiency, reduce cycle times, and increase productivity (Figure 1).  

In one redesign, after a mold flow simulation revealed hot spots on the tips of the parts, SyBridge experts engineered precision water channels to enhance cooling efficiency. Their unique design focused on cooling the front tip of the part, which enhanced the cooling of the rest of the part. This design change substantially reduced mold-open time. Figure 2 dives deeper into the results of these conformal cooling design enhancements. 

It takes experience to design effective conformal cooling 

Additive manufacturing (AM or 3D printing) is an excellent avenue for designing conformal cooling. AM enables intricate and complex structures that closely conform to every shape of the part in a way that–depending on the part geometry and complexity–is not always possible with subtractive manufacturing. During the design phase, long before the part is molded, SyBridge engineers use mold flow simulation, virtual testing, and digital integration to configure and test the conformal cooling capacities.  

Can we help you reduce cycle times? 

As conformal cooling experts, SyBridge engineers know how to help you get the cycle times and efficiencies your product needs. Contact our team to explore how solutions like conformal cooling can improve your injection molding process.

The post Conformal Cooling: Impact By the Numbers appeared first on SyBridge Technologies.

Forget typical cycle times. We’re pushing the boundaries of conformal cooling.  While traditional approaches deliver reductions, at SyBridge, we see further.  By combining our expertise in 3D printing, mold tooling design, and in-house manufacturing, we engineer conformal cooling solutions that unlock the true potential of this transformative technology. Our unique synergy allows us to not just achieve impressive results, but to truly test the limits of what conformal cooling can accomplish for your product.   

Conformal cooling improves throughput 

SyBridge uses conformal cooling designs–either in retrofitting older tooling or as an initial design element–to enhance cooling efficiency, reduce cycle times, and increase productivity (Figure 1).  

In one redesign, after a mold flow simulation revealed hot spots on the tips of the parts, SyBridge experts engineered precision water channels to enhance cooling efficiency. Their unique design focused on cooling the front tip of the part, which enhanced the cooling of the rest of the part. This design change substantially reduced mold-open time. Figure 2 dives deeper into the results of these conformal cooling design enhancements. 

It takes experience to design effective conformal cooling 

Additive manufacturing (AM or 3D printing) is an excellent avenue for designing conformal cooling. AM enables intricate and complex structures that closely conform to every shape of the part in a way that–depending on the part geometry and complexity–is not always possible with subtractive manufacturing. During the design phase, long before the part is molded, SyBridge engineers use mold flow simulation, virtual testing, and digital integration to configure and test the conformal cooling capacities.  

Can we help you reduce cycle times? 

As conformal cooling experts, SyBridge engineers know how to help you get the cycle times and efficiencies your product needs. Contact our team to explore how solutions like conformal cooling can improve your injection molding process.

The post Conformal Cooling: Impact By the Numbers appeared first on SyBridge Technologies.

Ron Maillet, General Manager of SyBridge Technologies in Fitchburg, Massachusetts, is an injection molding expert who started as an apprentice nearly forty years ago in Fitchburg, Leominster, Clinton, and surrounding areas. 

For the past twenty-four years, Maillet has been working in the same building, in many roles and increasing responsibilities, and even through ownership changes. Now in the leadership role at SyBridge Technologies-Fitchburg, he helps oversee a well-established apprenticeship program with students from Montachusett Regional Vocational Technical School (“Monty Tech”) to learn the art, science, and craft of mold-making. 

“It’s fitting that this area would be home to a thriving apprenticeship program in plastics and mold-making,” said Maillet. “One hundred years ago, Foster Manufacturing – famous for Foster Grant glasses – pioneered plastics and injection molding five miles away in Leominster,” said Maillet. The industry has had a presence here ever since.  

SyBridge Technologies in Fitchburg has partnered with Monty Tech for seven years, bringing students into apprenticeship programs and then on into full employment. All the students that have started as apprentices under Maillet are either still in apprenticeship or are now employed by SyBridge, a testament to the staying power of the training and the industry. 

Kim Curry, Coordinator of Co-operative Education and Placement for Monty Tech, explained the breadth of the apprenticeship program. Monty Tech serves 18 cities and towns in the area and offers 21 vocational programs, including “Advanced Manufacturing.”  For a student to be considered for the co-operative education program, the student must be a junior, maintain grades of 75 or better, and be free of any discipline issues. The co-operative education program has seen a steady growth in interest from students since 2018. 

“It’s been a great partnership between SyBridge and Monty Tech,” said Curry. “When I do site visits there, I see my former students in mentorship and supervisor roles—and it is such a delight!” 

First comes the blueprint 

Every SyBridge apprentice starts in the same way Maillet began: reading a blueprint. From the blueprint, they sort out the cuts and angles, note the dimensions and tolerances, and then schedule the order of each process. The apprentice then moves to a manual milling machine, where they install the tools, calculate cutting speeds, and make their first test cuts.  

“I started reading blueprints,” said Jake Rickan, a 2023 graduate from Monty Tech who recently signed on as an employee of SyBridge. Rickan became interested in tool design and machine tech during his exploratory section in school, where he learned about different functional areas. He had been tinkering with after-market car parts, which involved machining, and the work of the apprenticeship program “caught his eye.” 

“I had always been infatuated with machining,” said Jake. His parents were both educators, but for Jake, machine technology and the finished, machined piece of steel has its own appeal. “It’s very cool to see the finished piece and be like, ‘Hey, I’m the one who did that,’” said Rickan. 

Step by step through the apprenticeship 

“Once they show us they’ve [mastered a particular skill], then we move them on to the next stage,” said Maillet, “For instance, after showing they can run the manual machines, we move them to milling equipment with numerical controls. Then they start programming with computers; using 3D files created by our engineers, they start actually cutting steel.” Eventually, they get to the 16-tool changer and the higher-end work. And then on to another department. 

Along the way, apprentices meet with both the experienced staff at SyBridge and with Monty Tech faculty to review expectations. Each step of advancement through the apprenticeship comes only after demonstrating the ability to perform previous steps.  

“Students record each of the skills they learn every day,” said Maillet. Those records become a valuable reference document throughout their journeys as apprentices, and as they move into full-time employment. 

The Monty Tech/SyBridge apprenticeship program enrolls one student per year. The program alternates weeks students spend attending school and working at SyBridge, so skills can be reinforced in both the apprenticeship program and classes. 

“It’s cool to be able to come to the workplace and say, ‘Oh, what they’re teaching us [at school] is actually very useful,’” said Rickan.  

Learning outside the lecture hall 

One of the highlights of the apprenticeship program is that former students pass on the skills and habits they have learned to newer students. Students share the tacit knowledge they pick up from experienced mold-makers and machinists, like securing workpieces, locating the zero point (starting position) on the workpiece, and keeping their work area very clean. This is especially important for the precision work that SyBridge is known for; starting with a clean mill ensures debris from previous jobs will not alter tolerances for the next job. 

“We have a very strong emphasis on making sure the part [in process] falls within certain tolerances,” said Rickan. In addition to setting up the workspace properly and having the specialized equipment required for precise tolerances, “we need to know how to get the part within those tolerances.” 

Toward expertise that invents tomorrow’s tooling  

Maillet likes to say that while most people divide an inch into quarters, eighths, and sixteenths, he and the highly specialized journeymen machinists at SyBridge divide an inch into 10,000 sections.  Here, tools are regularly manufactured with .0002” tolerances (as compared to a standard sheet of printer paper which is about 20 times thicker at .004”). Observing and maintaining tolerances is critical to any machined part moving forward. That ability to work with very tight tolerances is an uncommon one; it’s also why the new apprentice enters the program only after being vetted by Monty Tech staff and instructors. Throughout their program, class subjects dovetail with real-world experience at SyBridge to reinforce skills that will prove useful over a lifetime.  

Training students with experienced machinists has proven to be very productive for Maillet. Maillet noted that when he ran an ad for an experienced machinist, “90% of people don’t even know what a machinist is.” Meanwhile, Monty Tech (which is half a mile from SyBridge) has 25 potential students who are already interested and poised to learn new machinist skills. The bottom line is that Maillet can train and then hire experienced workers right into his shop —resulting in a scenario that benefits the students and the company.  

“As an industry, we are actually in a time of rebuilding our skills here in the US,” said Maillet. “Tooling and mold-making were strong in the 1980s and 1990s, but then moved offshore for a lot of years.” After COVID-19 and the renewed focus on supply chain management, Maillet noted that interest in skilled mold and tool making had surged.  

Rebuilding the craft of injection mold tooling means students remain in the community, earn a good salary, and help advance the art and science of mold-making. 

The post Apprenticeship Program Serves Students and the Tooling Community appeared first on SyBridge Technologies.

Designing a product is just the beginning. The real challenge lies in ensuring your design is manufacturable, cost-effective, and meets your quality standards. Waiting for design feedback, navigating last-minute design changes, and dealing with manufacturing issues can make this journey feel like an uphill battle. But there’s a solution to make this process smoother and more efficient. 

We’re excited to introduce the SyBridge Studio App, a powerful new tool now available in the Onshape App Store. Developed by leading global manufacturer SyBridge Technologies, the app brings the existing features of SyBridge Studio directly into Onshape. Leveraging insights from millions of parts and tools made combined with the power of artificial intelligence, it codifies a century of manufacturing knowledge to provide you with expert guidance at your fingertips. Easily confirm manufacturability, understand trade-offs, and optimize your design, all while meeting your goals for cost, speed, and quality. 

Manufacturing insights at your fingertips 

After subscribing to the app, you’ll instantly get access to the following features: 

Automated Design Feedback – Quickly find ways to improve part design and reduce costs with manufacturing recommendations. Get feedback on draft angles, non-standard holes, supported surfaces, surface imperfections, and more. Understand how to mitigate potential manufacturing risks with a collective 80+ Design for Manufacturability (DFM) checks available across six manufacturing processes: injection molding, CNC machining, and four 3D printing processes (DLS, FDM, MJF and SLA). 

Injection Mold Action & Insert Identification – See where your tooling requires actions such as slides, pins, inserts, lifters, bosses, or strippers. Use this to make informed design modifications that minimize witness marks and enhance the aesthetic quality of your part. Identify opportunities to reduce tooling complexity and costs, streamlining the manufacturing process and improving overall efficiency. 

Part Thickness Analysis – Visualize the material distribution in your part with a full-field colored heatmap to easily identify thin or thick wall issues. Maintaining consistent wall thickness ensures uniform cooling, minimizes warping, and enhances part strength, durability, and aesthetic quality. Use this analysis to make informed design modifications that improve part quality and reduce costs by normalizing wall thickness throughout your design, resulting in a more efficient and effective manufacturing process. 

More features in an expanded view – SyBridge Studio’s Onshape extension currently houses the most important features, but even more are available on the SyBridge Digital Platform, including instant quoting, parts ordering, and additional analysis tools. Log in here using the same email used to sign in to the SyBridge Studio Onshape app to continue working in a more immersive, full-screen view. 

And more coming soon

More advanced features to help you design more effectively and bridge the gaps between design and manufacturing are on the way, including: 

Instant pricing and cost insights – Receive estimated part and tool pricing at various quantities, access cost-saving design recommendations, understand cost breakdowns, and view other key cost drivers (e.g., cycle time) for 6 manufacturing processes. 

Purchase parts – Easily place an order for your part when you’re ready to check out, directly inside Onshape.  

Recommended and customizable manufacturing orientation – Use our recommended manufacturing direction or adjust it based on aesthetic requirements. Easily visualize and understand the impact on design recommendations and tooling requirements. 

Injection molding tool visualization – View a mock-up of the mold core and cavity to get a sneak peek at how your tool will be made. 

Additional insights – Intelligent systems meet intelligent design. Stay tuned for more insights coming your way: material insights, more advanced DFM checks, and additional injection molding guidance. 

Assembly support – The SyBridge Studio app currently analyzes individual components that you select. Next up is support for full BOMs/assemblies. 

Elevate your design process today 

The SyBridge Studio App is here to change the way you approach design and manufacturing. By integrating advanced manufacturability analysis and optimization tools directly into your Onshape workflow, this app aims to help you overcome common challenges and achieve your design goals more efficiently. 

Ready to take your design process to the next level? Head to the Onshape App Store and subscribe to the app today to experience firsthand how this powerful tool can transform your workflow and bring your designs to life with greater ease and precision. 

The post AI-Powered DFM Analysis by SyBridge, Now Available in the Onshape App Store  appeared first on SyBridge Technologies.

Get the full article at MoldMaking Technology

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In today’s competitive landscape, manufacturers are constantly seeking ways to streamline their processes, reduce costs, and increase output. At SyBridge, we understand these challenges and are dedicated to partnering with you to achieve your manufacturing goals.

Our expertise in design, engineering, and tooling for injection molding goes beyond simply creating high-quality molds. We are your strategic partner, offering expert guidance to optimize your entire process, resulting in measurable improvements to your bottom line.

Case Study

Optimizing a Pail Mold for Increased Efficiency and Cost Saving

A recent collaboration with a client perfectly exemplifies the value SyBridge brings to the table. We were tasked with re-engineering an existing pail mold. The original design presented several challenges, including:

• Average cycle times: The initial cycle time was 20 seconds, limiting overall production output.
• Limited output: The mold could produce 1 million parts per year; however, growing demand required additional output.

SyBridge’s Expertise Delivers Remarkable Results:

Our team of engineers meticulously analyzed the existing mold and identified optimization opportunities. By leveraging our expertise in precision tooling and complex high-cavitation tools, we were able to:

• Reduce cycle time by 15% (3 seconds):
  This seemingly small improvement translates to significant production volume increase over time.
• Increase output by over 30%:
  The new design allows for the production of 1,350,000 parts per year, exceeding the client’s initial requirements.
• Consolidate production:
  The optimized mold’s increased efficiency enabled the client to manufacture at the same rate as four presses while using only three, eliminating the need for additional equipment and tooling costs.

The Impact

Measurable Cost Savings and Increased Profitability

These improvements translate into tangible financial benefits for our client. They were able to:

• Avoid the significant expense of purchasing and integrating a new injection molding press.
• Eliminate the cost of additional tooling required for a four-press operation.
• Realize increased production capacity to meet growing demand and potentially capture new market opportunities.

Beyond Efficiency

Maintaining Product Integrity

It’s important to note that these improvements were achieved while maintaining the product’s critical performance requirements. The new mold design successfully met all drop testing, shipping testing, and leak testing specifications, ensuring product integrity without compromising efficiency.

SyBridge

Your Partner for Optimal Injection Molding Solutions

This case study is just one example of how SyBridge’s expertise can help manufacturers optimize their injection molding processes and achieve significant cost savings, increased output, and improved profitability. Our commitment to precision engineering, innovative solutions, and collaborative partnerships makes us your ideal partner for navigating the ever-evolving landscape of injection molding.

The post Optimizing Your Injection Molding Process for Cost-Effective Manufacturing Excellence appeared first on SyBridge Technologies.

In the fast-paced world of manufacturing, efficiency is paramount. Every second shaved off a cycle time translates directly to higher profits and a competitive edge. And when it comes to injection molding, tooling design is often the foundation upon which everything rests. At SyBridge, we understand this, and it’s why we’ve become the industry leader in design, engineering, and manufacturing of injection mold tooling.

Our expertise goes beyond simply creating high-quality tools. We are experts in optimization, and our dedication to understanding your specific needs allows us to craft solutions that streamline your entire injection molding process.

A Real-World Example

Supercharging Production

One client, a manufacturer of plastic dosing scoops, faced a common challenge: production couldn’t keep up with demand. They were running four 175-ton injection molding machines 24/7. Each existing 12-cavity tool had a 9.5-second cycle time and produced 110,000 parts per day, but it simply wasn’t enough.

Phase 1

SyBridge engineers evaluated the customer’s existing equipment, systems, and output needs, then designed a new 12-cavity tool using innovative solutions for filling and cooling the component. Upon installation, they realized a remarkable 5.0-second cycle time, a 47% reduction from their previous 9.5-second cycle time. This translated into an 88% increase in daily production with the same machine, producing an impressive 207,000 parts per day.

Phase 2

But SyBridge didn’t stop there. Building on this success, we engineered another tool, this time with 16 cavities; as before, the cycle time was at 5-seconds, and the higher-cavitation tool was still able to run in the same 175-ton presses. This powerhouse pushed daily production even further, reaching 275,000 parts – a 150% increase from the original tool.

The Proof is in the ROI

The impact was undeniable. The manufacturer not only met demand but was also able to get ahead of it, opening up opportunities for new sales growth. SyBridge tooling solutions delivered such significant production gains that the customer was able to recoup their tooling investment in less than 6 months, a testament to the immediate value delivered by SyBridge expertise. But even beyond the initial investment payback, with the increased output, the customer was able to better schedule planned maintenance, extending the life of the tools and leading to additional long-term financial benefits. This is just one example of how SyBridge empowers our partners to achieve remarkable results. Our commitment to precision engineering, coupled with our in-depth understanding of the injection molding process, allows us to:

• Reduce cycle times through innovative tool design, leading to greater output and increased production efficiency.
• Lower your Total Cost of Ownership (TCO) through more efficient tooling that drives lower direct and indirect material costs for molded products.

Ready to unlock the full potential of your injection molding process?

At SyBridge, we are more than just toolmakers; we are your optimization partners. We understand the unique challenges you face and are committed to developing solutions that not only meet your needs but exceed your expectations.

Contact us today to discuss your specific needs and discover how our expertise can help you achieve breakthrough results:

• Faster cycle times
• Increased production output
• Reduced total cost of ownership
• A competitive edge in the marketplace

The post How SyBridge Expertise Optimizes Your Process and Lowers Costs appeared first on SyBridge Technologies.

In this fast-paced market, where consumers crave both luxury and sustainability, staying ahead of the curve is crucial. This article delves into the key trends transforming the industry, from captivating design elements to eco-conscious solutions, empowering you to create packaging that not only looks good but resonates with today’s savvy consumers. 

Product differentiation drives sales 

In an increasingly crowded marketplace, creating a unique style for cosmetic packaging is key to catching the eye of consumers and building brand loyalty. Consumers look for details in the design, such as embossed logos on caps, custom colors, unique materials like copper and aluminum, and exclusive shapes (Figure 1). 

Figure 1. Distinctive shapes and mixed materials help products stand out in the beauty market.  

Consumers also expect a luxe feel when purchasing a beauty product with a high price point. Using substantial materials in packaging gives even miniature products a high-end feel.  

Additive manufacturing supports new product development  

Developing products with novel designs requires expertise and options for scaling if products become popular. Since the cosmetics industry moves quickly, bringing a new product from conception to design to reveal is essential for its relevance. And because customer preferences can pivot rapidly, manufacturing a limited number of new products using cost-effective techniques to test the market is also important.  

Additive manufacturing processes like 3D printing meet both requirements—they can produce parts quickly and don’t require huge upfront costs (Figure 2). 

Figure 2. Carbon® Digital Light Synthesis™ is one of SyBridge’s many 3D printing techniques 

Companies can scale production with high cavitation injection molds or other production techniques if the product is commercially viable. Although specialty tooling capabilities may have a higher upfront cost, their ability to support higher production runs and longer lifetime cycles ensures they remain cost-effective. The ability to start small and scale ultimately results in the lowest overall cost of ownership for brand owners.  

Using sustainable materials and designs to appeal to consumers  

Sustainability continues to be a trend for consumer products in 2024, including cosmetic packaging. However, most consumers are unwilling to compromise on increased prices for more sustainable products. Manufacturers must find a way to produce sustainable packaging that is also cost-effective.  

Toward more sustainable cosmetic packaging  

Refillable and reusable packaging is emerging as a more environmentally friendly alternative to single-use packaging. Other sustainability trends include using either post-consumer recycled (PCR) plastic or aluminum for manufacturing or creating products made of single, recyclable plastics (mono-material) instead of a mixture of plastic and metal (Figure 3).  

Figure 3. Material selection simplifies sustainability for consumers 

Mono-material packaging simplifies recycling but does come with challenges, such as finding plastic alternatives to metal springs and other traditional metal components. Manufacturers are also limited in design by choosing mono-material packaging because they can’t use decorative metal coatings.  

A simple way to meet the demand for sustainable packaging without making consumers pay more for beauty products is by choosing a minimalist design (Figure 4). Sleek designs without added decorative features can reduce production complexity and material usage. The challenge to choosing minimalist designs is standing out in a market that relies so much on eye-catching products.  

Figure 4. Minimalist designs can reduce material usage and simplify production  

Design services help meet manufacturing challenges  

Producing flawless cosmetic packaging with the luxe feel consumers expect using sustainable materials is a serious challenge. That’s where working with companies with design services and a range of manufacturing capabilities becomes essential. SyBridge experts can complete design for manufacturability (DFM) checks and simulation analysis to identify production issues before production begins, reducing design iterations and saving on production costs (Figure 4). 

Figure 5. DFM checks help determine how to manufacture the highest-quality part at the lowest possible cost per unit. 

Design services are essential not only for testing novel ideas but also for optimizing current production. SyBridge experts can use product data and analytic tools to create a digital thread — a centralized source of truth for the part. We use the digital thread to gain insights about a part’s lifecycle (design to final production) and see opportunities for increased efficiency and improved quality (Figure 5).  

Novel dispensing methods make for more hygienic products  

A carryover from the COVID-19 pandemic continuing to influence health and beauty products is an emphasis on hygiene. Where many skincare and makeup products require brushes or even a fingertip for application, consumers are now choosing contactless options like droppers, misters, products with internal applicators, and airless pumps.  

Airless pumps reduce the chance of harmful bacteria getting into beauty products during use or illnesses spreading between people sharing the product (Figure 6). Pump dispensers also give customers precise control over how much product they use because each pump produces an exact volume. Companies can use pumps as an opportunity to provide instant brand recognition through contoured pump heads and other unique details.  

Figure 6. Airless pumps help reduce the spread of microbes and regulate dosing. 

In addition to enhanced hygiene and dosing control, the airless packaging used in pumps and sprays can preserve the chemical composition of the formula by not introducing oxygen during use. This extends the product’s shelf life. Airless packaging can help reduce waste, and it is often made from mono-material, making it 100% recyclable.  

Manufacturing for optimal user experience and safe shipping 

A challenge for manufacturing novel dispensing methods is ensuring function. Consumers can easily become frustrated and dissatisfied when features such as pumps malfunction, ultimately costing brands the loyalty they have worked hard to gain. Precise manufacturing is essential to avoid warpages, stress cracks, and other flaws that can cause packaging to malfunction. 

E-commerce companies selling cosmetics also need packaging that meets shipping standards. Products must have the strength to withstand rough handling during transportation, sortation, and distribution.  

SyBridge helps companies manufacture uniform, strong products by incorporating quality inspection services and advanced designs, such as conformal cooling, in our manufacturing technology. Our precision manufacturing can help companies achieve high-feature, aesthetic parts that are also functional. 

Partnering with SyBridge  

Manufacturing partnerships help cosmetics companies maintain a competitive edge in the fast-paced industry. Since needs vary by product, partners with multiple capabilities are especially valuable and critical to support reduced overall tooling costs. SyBridge experts can help cosmetics packaging manufacturers wherever they are—whether seeing if a novel design is achievable or choosing the best manufacturing technology for a proven product.  

Staying ahead of 2024 beauty trends is possible with the right partners. Connect with a SyBridge expert today to learn how our comprehensive services can help you meet your goals this year.  

The post 2024 Trends in Cosmetic Packaging appeared first on SyBridge Technologies.

Defects can reduce the speed and cost-efficiency of the entire product development process, and can potentially shorten product life spans if left unchecked. Injection molding issues and defects can be caused by a host of reasons, including poor design, production process mistakes, quality control failures, and more. As such, it’s important to take a proactive approach to risk mitigation throughout the product development process so as to reduce the chances of potential injection molding defects.

Here are a few of the most common defects that may occur in plastic injection molding — and how product teams can avoid them.

1. Flow Lines

Flow lines are off-color lines, streaks, and other patterns that appear on the surface of a part. These are caused by the shot of molten plastic moving at different speeds throughout the injection mold, which ultimately causes the resin to solidify at different rates. This is often a sign that injection speed and/or pressure are too low.

Flow lines can also appear when the thermoplastic resin moves through parts of the mold with different wall thicknesses — which is why maintaining consistent wall thickness or ensuring that chamfers and fillets are an appropriate length is critical. Placing the gate in a thin-walled section of the tool cavity can further help to reduce flow lines.

2. Sink Marks

Sink marks appear as depressions, dents, or craters in thick sections of a part. Thicker sections take longer to cool, which can have the often unanticipated side effect of the inner portions of the part shrinking and contracting at a much different rate than the outer sections.

Though most often an indicator that the plastic needs more time inside the mold to properly cool and cure, sink marks may sometimes be remedied by reducing the thickness of the thickest wall sections, which helps to ensure more even and thorough cooling. Inadequate pressure in the mold cavity or higher-than-desirable temperatures at the gate can also contribute to the development of the defects.

On the design side, the risk of sink marks can be minimized by ensuring proper injection molding rib thickness and wall thickness. These actions can also help to increase the overall strength of the part.

3. Surface Delamination

What is delamination? Delamination is a condition that causes a part’s surface to separate into thin layers. These layers, which appear like coatings that can be peeled off, are caused by the presence of contaminants in the material that do not bond with the plastic, creating localized faults. An over-dependence on mold release agents can also cause delamination.

To encourage delamination repair and prevention, teams should increase mold temperatures and tailor the mold ejection mechanism to be less dependent on mold-release agents, since these agents can increase the risk of delamination. Properly pre-drying the plastic before molding can also help.

4. Weld Lines

Also called knit lines, these defects mark where two flows of molten resin came together as they moved through the mold geometry. This happens around any part of the geometry that has a hole. As the plastic flows and wraps around each side of a hole, the two flows of plastic meet. If the temperature of the flow isn’t just right, the two flows won’t properly bond together and will instead cause a visible weld line. This reduces the overall strength and durability of the component.

Raising the temperature of the molten resin can help to prevent the solidification process from beginning too soon, as can increasing injection speed and pressure. Resins with lower viscosity and lower melting points are less prone to developing weld lines in injection molding, which can also be eliminated by removing partitions from mold design.

5. Short Shots

“Short shots” refer to instances in which the resin doesn’t entirely fill the mold cavity, resulting in incomplete and unusable parts.

What causes short shots in injection molding? Typically, they are the result of restricted flow within the mold, which can be caused by gates that are too narrow or have become blocked, trapped air pockets, or insufficient injection pressure. Material viscosity and mold temperature are also contributors. Increasing mold temperature and incorporating additional venting into mold design to allow air to properly escape can help prevent the occurrence of short shots.

6. Warping

Injection molding warping refers to unintended twists or bends caused by uneven internal shrinkage during the cooling process. Warping defects in injection molding are generally the result of non-uniform or inconsistent mold cooling, which creates stresses within the material.

Preventing warpage defects in injection molding is a matter of guaranteeing that parts are given enough time to cool — and at a sufficiently gradual rate — to prevent internal stresses from forming and damaging the piece. Uniform wall thickness in mold design is crucial for many reasons, critical among them being that it helps ensure that the plastic flows through the mold cavity in a single direction.

It’s worth noting that materials with semi-crystalline structures are more likely to develop warping.

7. Jetting

Jetting defects in injection molding are another potential result of an uneven solidification process. Jetting occurs when an initial jet of resin enters the mold and has enough time to begin setting before the cavity fills. This creates visible, squiggly flow patterns on the piece’s surface and decreases the strength of the part.

Reducing injection pressure is often the best way to ensure more gradual fills, but increasing the mold and resin temperature can also help to prevent any jets from preemptively setting. Placing the injection gate so that the flow of material runs through the shortest axis of the mold is another effective means of minimizing jetting.

Prevent Injection Molding Defects and Causes

Injection molding can be a highly efficient manufacturing method for producing highly repeatable plastic parts, but, as with many processes, producing high quality end-parts requires a high level of attention to detail and a proactive approach to risk management. Everyone involved in the product development process — from the initial design and proof-of-concept stages all the way to fulfillment — needs to do their due diligence to ensure products meet the highest quality standards and avoid these common plastic injection molding issues.

Choosing a manufacturing partner like SyBridge, who is well-versed in common defects in injection molding and their troubleshooting, can mean the difference between high-quality parts — produced on-time and within budget — and those marked with weld lines, jet, flash, sink marks, and other defects. In addition to being an experienced on-demand manufacturing shop, we also provide design consulting and optimization services that ensure we’re able to help every team create functional, elegant, high-performance parts as efficiently as possible. Contact us today to learn more about our injection molding services.

The post 7‌ ‌Common‌ ‌Injection‌ ‌Molding‌ ‌Defects‌ ‌and‌ ‌How‌ ‌to‌ ‌Avoid‌ ‌Them‌ appeared first on SyBridge Technologies.

The urethane casting build process involves first creating a master pattern — essentially a replica (often 3D printed) of the final part. The pattern is then fully encased in liquid silicone and allowed to cure. The mold is cut into halves and the pattern removed. From there, the process can be repeated using the proper urethane casting resin.

Polyurethane casting materials are capable of providing performance characteristics comparable — if not superior — to the thermoplastics used in injection molding. However, as with other production methods, the process of casting high-quality parts that meet all performance requirements also requires that product teams follow design for manufacturability (DFM) best practices. Here are some of the most important guidelines for product teams to keep in mind:

Tolerances

Some degree of variation is inevitable in manufacturing (though teams should endeavor to account for as many of the variables as possible), and tolerances are the acceptable amount of dimensional variation between individual units. Cast urethane tolerances are typically around  ± 0.015” or ± 0.003 per inch, whichever is greater. Tighter tolerances may be offered on a case-by-case basis.

In general, a shrinkage rate of +0.15% is typical. This is caused by the thermal expansion of the urethane casting material and how the flexible silicone mold warms in response.

Additionally, it’s important to note that while urethane cast parts take well to post-processing (though additional processes, such as polishing or custom finishing, can quickly drive up production costs), some design features like sharp corners or lettering may experience slight rounding in the cooling process, impacting the definition of finer details. That said, it is possible to add a finish to the master pattern that mimics an SPI finish or texture. You can also paint urethane cast parts to match Pantone colors, and certain color and pigments can be added directly to the casting materials, as well.

Wall Thickness

Parts produced with urethane casting should have a minimum wall thickness of 0.040” (1mm), though walls as thin as 0.020” (0.5mm) can be achieved for some small components. Larger parts generally require thicker walls in order to ensure the piece’s structural integrity.

Urethane casting does allow for parts with varying wall thicknesses or irregular geometries, but designing parts as such should be done only when strictly necessary. Maintaining a consistent thickness helps to minimize the potential for improper shrinkage and deformation during the curing process.

Undercuts and Draft

While undercuts can quickly complicate injection molding design, the flexible nature of the silicone molds used in urethane casting typically allows for parts to be removed easily and without damage.

The same is true for draft angles: they are a necessity for ejecting pieces from metal molds, but less essential for urethane-cast parts. That said, incorporating 3-5 degrees of draft into part design can significantly reduce strain on your mold and extend its life cycle.

Ribs

Ribs add stability and strength, but it’s important to ensure that they are oriented so as to maximize the bending stiffness of the walls they support. As a general rule of thumb, the rib’s height should be no more than three times its width, and the width of the rib where it meets the part wall should be between 40-60% of the wall thickness. Lastly, to maximize the strength of the rib, all interior corners should have a fillet radius of at least 25% of the part’s wall thickness.

Bosses

Bosses allow secure mating parts to be attached through the use of screws, pins, and other fasteners. As with ribs, the base radius should be about 25% of the part’s wall thickness, which has the added benefit in this case of helping to prevent the fastener from burning when it’s set into the boss.

Interior boss corners should use a 0.060” (1.5mm) fillet radius to minimize thickness and reduce the likelihood of sinks developing. Ensuring that bosses are no more than 60% of the nominal wall thickness also helps to minimize shrinkage.

Leverage the Benefits of Urethane Casting Today

The advantages of urethane casting — short lead times, low cost, and design and material flexibility, to name a few — only truly pay off if you adhere to design and manufacturing best practices. This means paying attention to variables like urethane casting material properties, general tolerances for rubber parts, and everything in between — which quickly becomes complicated without the assistance of an experienced manufacturing partner.

With our agile approach, we’re able to significantly shorten lead times and increase operational efficiency for product teams of all shapes and sizes. And at SyBridge, our business isn’t just based on manufacturing superior parts — we also work tirelessly to make sure that our production processes are as efficient as possible, even if that means using a combination of techniques to get the job done. Contact us today to learn more.

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