We have many different conversations with clients and prospective businesses each day where questions are asked. Due to the complexity of what we do, we have in this section of our website, some of the more frequently asked questions. If your question isn't hrere, then please feel free to call us on 01626 830113 and ask a member of our team!
Q: How do I design a product for manufacture
A: You don’t! This is a very specialist area where a product design agency will be able to guide you through every step you need to make sure your product can actually be made – and made to the right specification. You can find out more about our product design services here.
Q: Why is the tooling so expensive?
A: Full hardened steel is not a low cost commodity, and the work involved in cutting steel for the complex design of an injection mould tool takes expensive equipment, skilled personnel and a lot of time.
Q: Why does it take so long to get a Fully Hardened Tool made
A: It takes time to get things right! You should usually see first off samples within the first 6/8 weeks – this is the time it takes to design the tool, and design the cavities so that the tool can produce a sample of your item. This first sample, or T1, will not have any texture but it will be a good representation of the item so that it can be tested for fit and function. T2’s will have any modifications that are needed, and T3’s will normally be a good representation of the finished item, to include surface finish and all features ready for you to sign off.
Q: Can I reduce the time it takes to manufacture a tool
A: Yes, there are other methods of tooling for low volume manufacture, but you will always get what you pay for – so the tool life may be 10’s or 100’s of products rather than the hundreds of thousands offered by a fully hardened Injection Mould Tool.
Q: Aren’t plastics bad for the environment?
A: Items that are disposed of, rather than recycled, are the biggest issue this planet faces. Plastic carrier bags for example cause a huge amount of Ocean pollution, whereas, most injection moulded items have been designed to be used, repaired or recycled. This recycled plastic can then be re-granulated and used again to make something else. You can read more about Amtek's recycling policy here.
Q: Explain the term ‘thermoset polymer’, with reference to molecular structure.
A: Once 'set' these plastics cannot be reheated to soften, shape and mould. The molecules of these plastics are cross linked in three dimensions and this is why they cannot be reshaped or recycled. The bond between the molecules is very strong.
Q: Explain the term ‘thermoplastic’, with reference to molecular structure.
A: These plastics can be re-heated and therefore shaped in various ways due being long chain monomers that are not inter- connected. They become mouldable after reheating as they do not undergo significant chemical change. Reheating and shaping can be repeated. The bond between the molecules is weak and become weaker when reheated, allowing reshaping. These types of plastics can be recycled.
Q: What Are The Advantages Of Plastics Over Metals?
Easy to handle
Q: What Is Mfi?
Flow capacity of different grades of thermoplastics are inversely proportional to molecular weight.
Q: What are Fillers And Additives?
Adding of small molecules to plastics to get some characteristics (color, flexibility etc.). Fillers are commonly used with thermosetting plastics. Additives are of two types,
Physical means such as plasticizer
Chemical means--- stabilizer.
Q: What Are The Mold Release Agents?
External with mold surface e.g. Polyvinyl alcohol
Internal with resins eg. Silicon oil
Q: What Is Injection Capacity Or Short Capacity?
Maximum volume material injected by the screw during one cycle of operation.
Q: What Is Plasticizing Capacity ?
It is the amount of material that can be processed by the machine per hour. It is expressed in kg/h.
Q: What Is Injection Pressure?
It is the maximum pressure by which the material is injected through the nozzle. It is given in kg/cm2.
Q: What Do You Meant By Clamping Force?
It is the maximum force that the clamping system can exert on the mold or it is the maximum force by which the mold halves can be closed together. It is given in ton or kilo Newton.
Q: What Are The Types Of Injection Mold ?
Two plate mold
Three plate mold
Hot runner mold
Insulated runner mold
Hot manifold mold
Q: What Is Two Plate Mold ?
Mold which consists of core and cavity situated in plates. It is logical type tool where component require large gate. For simple type components there is only one daylight.
Q: What Is 3 Plate Mold?
It consists feed plates with core and cavity.
Q: What Is Hot Runner Mold?
In this, runner kept hot to keep the molten metal into fluid state also called runner less mold. In this, runner contained in a plate of its own runner section of the mold is not opened during molding cycle.
Q: What are the Advantages Of a Hot Runner
No molded side products
No separating of gate
Cycle time can be reduced
Q: What Is Insulated Runner Mold ?
It is a variation of hot runner mold in this type of molding. The outer surface of the material in the runner acts as a insulator.
Q: What Is Hot Manifold Mold ?
This is a variation of the heated hot runner and not the runner plate. This is done using electric cartridge.
Q: What Do You Meant By Stacked Mold?
A stacked mold is a multiple two plate mold with mold placed one over the other. A stacked mold construction doubles the output from a single molding machine and requires the same clamping force.
Q: Explain About Injection Molding?
In this process, the plastic material is injected in to the mold through a sprue bush by means of a screw plunger. This process can be used for both thermosetting and thermoplastic materials.
Q: What Is Compression Molding?
In this process, the plastic material is placed in the cavity and use a force for compressing the compound as the mold closes, these molds are generally used for thermosetting materials.
Q: What Is Transfer Mold?
In this process, the plastic materials is transferred from a transfer pot and then forced in to the cavity by means of plunger. This method is used for molding thermosetting materials only.
Q: What is Blow Molding ?
Blow molding is very much like compression molding because the blow mold generally closes on a hollow shape that has been deposited in between the halves of the mold. Air or gas pressure is introduced at the center. This internal pressure causes a flow of the heated material in to intimate contact with the relatively cold mold sections. Here the plastic material solidifies and is subsequently ejected.
Q: What is Vacuum Molding?
The mold used for this process is similar that of the female half of the compression or blow mold auxiliary equipment on the machine heats the material and drags it over the cavity as indicated by the precise technique chosen.
Q: What is Rotational Molding?
The machine provides the means of holding the mold and rotating it about two axis at the same time. This rotation causes the powdered material that was loaded in to the mold before it was clamped in to the machine to solidify and cling to the wall of the mold.