Mould Design and Making: Choose the Right Mould Base and Insert

Generally speaking, standard mould base and standard parts can reduce making time and cost.

Commonly used mould bases in China include FUTABA, LKM, Minglee, and Skylucky. FUTABA is for medium and small sized mould bases, LKM, Minglee, and Skylucky are for big mould bases. In practice, mould price, structure, and processing complexity should also be taken into consideration.

If there’s special demands about mould base, we can modify part structure, sizes and material, even redesign mould base. Under this circumstance, we should provide detailed design paper to the supplier, and point out the differences between customed mould base and standard one when custom a special mould base.

1. Decide on the size of mould base and insert

According to plastic product’s dimension ( plane area and height) abd structure ( like side parting sliders), inserts’ size can be fixed, and furthermore, fix the size of mould base.

Mould base and insert size for common plastic moulds, the following is a reference.
  “A”—-Distance between insert sidd and plate side
       “B”—-Distance between fixed die insert bottom and plate bottom
       “C”—-Distance between moving die insert bottom and plate bottom
  “D”—-Distance between product and insert side
  “E”—-Distance between highest point of product and insert bottom
  “H”—-Thickness of moving plate ( when mould base is A type)
  “X”—-Product height
 plane area
“S”mm2
A
B
C
H
D
E
100-900
40
20
30
30
20
20
900-2500
40-45
20-24
30-40
30-40
20-24
20-24
2500-6400
45-50
24-30
40-50
40-50
24-28
24-30
6400-14400
50-55
30-36
50-65
50-65
28-32
30-36
14400-25600
55-65
36-42
65-80
65-80
32-36
36-42
25600-40000
65-75
42-48
80-95
80-95
36-40
42-48
40000-62500
75-85
48-56
95-115
95-115
40-44
48-54
62500-90000
85-95
56-64
115-135
115-135
44-48
54-60
90000-122500
95-105
64-72
135-155
135-155
48-52
60-66
122500-160000
105-115
72-80
155-175
155-175
52-56
66-72
160000-202500
115-120
80-88
175-195
175-195
56-60
72-78
202500-250000
120-130
88-96
195-205
195-205
60-64
78-84
The above datas are for common plastic moulds bases, for special plastic products, pay attention to the following points:

a. when product height exceeds (product height X≥D), D should be increased, the increased value D=(X-D)/2.

b. sometimes, insert size is adjusted according to the need of cooling system, so can get better cooling result.

c. if complex structure need special parting or knockout, or if side parting need sliders, adequate adjustment to insert and mould base size and plate thickness should be make according to different condition to ensure hardness of mould base.
2. Decide on plate height
Plate height sould be more than the ejection stroke by 5-10mm, so that when the ejection complete, ejector fixing plate will not bump into moving plate or carrying plate.

3. decide on integrate structure of mould base

After deciding on a gerneral mould base, we need to checkout the whole frame to ensure it is suitable for customer’s injection machine. We should check the dimension, thickness, max opening stroke, knockout system and ejection stroke, etc..

4. decide on insert material

Insert material should have four features: 1, hardness; 2, wearing quality; 3, intensity and ductility; 4, corrosion resistancy. Insert material is decided by the quantity of the products and the plastic type.

For making products made of common plastic such as ABS, PP, PC, P20 pre-hardened steel is adopted. If the quantity is relatively large, quenched tempering steel such as H13 is adopted.

For fine finished plastic products or transparent plastic products, like PMMA, PS, AS, or fiber glass material, corrosion-resistant stainless steel like 420 is adopted.

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