The design and manufacture of injection mould tools is one of the most crucial stages in producing plastic components. At this stage, you can either avoid costly mistakes and delays or fall into them—depending largely on the manufacturer and toolmaker you choose to partner with.
Working with a proactive and knowledgeable tool supplier during the tooling process can lead to significant cost savings, reduced weight, and faster production times. To get the best results, partnering with an experienced tool manufacturer who can optimise the injection mould tool design is essential. In this article, we’ll explore key steps a reputable supplier should take to ensure the success of your project.
Early Considerations for Injection Mould Tooling
One of the first steps when a supplier receives an RFQ (Request for Quotation) is to evaluate whether your component design is suitable for injection mould tooling. The design influences critical factors like feed positions, hot runner systems, and cavity finishes. Sharing detailed information, such as dimension tolerances and specifications, at this stage ensures accurate tooling estimates and a smoother design process.
The Impact of Material Selection on Tool Design
Choosing the right component material is essential for tool design. For example, materials with high glass content can increase tool wear, and those requiring high temperatures will affect the tool steel selection. Discussing material options with your supplier early can avoid challenges later in the production process. At ENL Group, we guide our customers through this selection process to ensure the best fit for their project.
Part Volumes and Tool Design
Accurate estimates of annual and batch quantities, as well as the total lifetime volume of your product, play a crucial role in determining your tool layout and material requirements. Consider both immediate and long-term volume needs. If demand increases, your current tool may need modifications or a larger setup. Share your volume projections with your supplier early to optimise the number of cavities and ensure the best tool design.
Budget Considerations in Tool Design
Your budget will influence the material specifications and whether your tool is manufactured in-house or offshore. Offshore manufacturing is a viable option for tighter budgets, but it’s essential to ensure that your supplier maintains high-quality control throughout the process. At ENL Group, we offer offshore tooling solutions while retaining design and management oversight, ensuring quality service at all budget levels.
The Tool Manufacturing Process: Feasibility Review
Before manufacturing begins, a feasibility review is essential to ensure your component design is suitable for production. A reputable supplier will work closely with you, using tools like DFM (Design for Manufacture) and flow analysis to identify potential design issues that could affect cost, quality, and project timelines.
Case Study: How Feasibility Testing Optimised Tool Design and Reduced Costs
Image 1: original part design
One of our customers approached ENL Group with a specific request: they needed a part with a perfectly smooth, blemish-free surface finish. However, during the initial feasibility testing, we identified a potential issue with the design. The ribs inside the part were too thick where they met the top surface, which would have caused sink marks on the outside – preventing the part from meeting the required surface quality standards.
Optimising the Design for Better Results
To solve this, our engineering team recommended a simple yet effective design modification: reducing the rib thickness where it joined the top surface. This adjustment not only eliminated the potential sink marks but also improved the overall design. As an added benefit, this change reduced the weight of the part, further optimising the manufacturing process.
Image 2: The amended design
The Results: Cost Savings and Improved Efficiency
The feasibility testing led to a highly optimised tool that delivered significant benefits to the customer:
- Material Savings: The reduction in part weight meant that less material was needed, resulting in cost savings.
- Faster Production: A lighter part also reduced the cycle time, which further contributed to cost-efficiency.
- First-Time Success: Most importantly, the tool produced high-quality parts on the first sample run, avoiding the need for costly reworks or delays.
By addressing design issues early in the process, we were able to save the customer both time and money, while ensuring the part met their exact specifications.
The Importance of Feasibility Testing in High-Quality Tooling
At ENL Group, high-quality tooling is critical, particularly for industries like automotive, where both high volume and stringent quality standards are essential. Our commitment to feasibility testing ensures that every tool we manufacture is capable of meeting these demanding requirements. This is why we only collaborate with top-tier suppliers who bring technical expertise, innovation, and quality to the table.
Hot Runner Feasibility Testing
Manufacturing tooling for high-end polymers can present significant challenges, especially when it comes to both tooling and processing demands. At ENL Group, we frequently tackle these challenges by working with Synventive, a trusted partner we’ve collaborated with for many years. When a project calls for hot runner systems, Synventive ensures that the design and quality are perfectly aligned with the tooling requirements. They conduct detailed feasibility testing, from simple pressure drop calculations to full cooling and warp analysis, ensuring optimal system performance.
Global Support and Expertise
With a customer base spanning across Europe and operations in the UK and Slovakia, ENL Group relies on Synventive for seamless support across various regions. Their ability to assist in both domestic and offshore tooling projects is essential to our success. When selecting a supplier, it’s crucial to ask, “Who are your technical tooling partners, and how do they support your global operations?” Having strong partners like Synventive ensures that your tooling and production needs are met efficiently, no matter the location.
Case Study: Hot Runner System for Increased Volume Production
In a recent project, we worked on two four-impression tools—one pre-mould and one over-mould—both equipped with Synventive hot runner systems. These tools were part of a fully automated production cell, with a robot transferring parts between the two. When our customer was awarded a new contract, the production volumes were set to increase significantly, requiring the creation of 12-impression tools to handle the demand. However, the tools still needed to fit within the same automated cell, which presented a unique challenge.
Balancing hot runner systems for 12-impression tools can be complex, as it adds bulk and increases overall tool size—an issue given the cell’s strict height restrictions. Initially, a 5-drop and 10-drop hot runner system were proposed, but they didn’t meet the size constraints. Synventive offered an alternative: a 6-drop and 12-drop system, which provided more design flexibility and allowed for better system balance.
The Result: 200% Production Increase, 30% Cost Reduction
By implementing Synventive’s solution, we successfully manufactured the new tools while keeping them within the existing cell’s constraints. The outcome? A 200% increase in production and a 30% reduction in part cost. This collaboration between ENL Group and Synventive highlights the importance of choosing the right partners who can deliver innovative solutions to meet both technical and production demands.
For complex polymers, hot runner systems are often necessary. At ENL Group, we partner with Synventive to ensure optimal performance of our hot runner systems. Their expertise includes pressure drop calculations, cool and warp analysis, and more, ensuring your tools are designed for success.For complex polymers, hot runner systems are often necessary. At ENL Group, we partner with Synventive to ensure optimal performance of our hot runner systems. Their expertise includes pressure drop calculations, cool and warp analysis, and more, ensuring your tools are designed for success.
Conclusion: Optimising Your Injection Mould Tool Design
To ensure your injection mould tools are cost-effective and optimised for long-term performance, it’s essential to work with a supplier who:
- Understands the importance of component and tool design.
- Guides you through material selection for consistency and reliability.
- Offers cost-effective solutions based on your production needs and tool lifespan.
- Uses hot runner systems to save materials, reduce waste, and improve cycle times.
- Manages both the tool design and production process for a seamless experience.
- Partners with credible technical experts to ensure long-term success.
Choose a partner who can meet your demands for quality, efficiency, and cost-effectiveness in your tool design and manufacturing process.
