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issue: November 2003 APPLIANCE Magazine

Plastics Buyers' Guide
The Value of a Well-Engineered Mold Base


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Molders are constantly looking for ways to produce consistent, high-quality parts, while maximizing output and uptime. One of the best ways to achieve this is through the use of an effectively engineered mold base.

From simple stripped closures to complex multi-material and unscrewing applications, a reliable mold base can improve output by helping to optimize cooling and cycle times. This is done through consistent and accurate alignment, rigid plate design, and smooth plate actuation of the mold base.

Molders can also maximize a system's uptime with a mold base that features durable components, accurate alignment for minimal wear and maintenance, easy access to components, and ease of setup.

Key components of an effectively engineered mold base include:
  • Manifolded water channels - Custom-sized to each application to ensure optimal cooling, minimal connections, and simple installation.
  • Robust ejection systems - Sized to meet the requirements of the application and configured to the molder's needs.

Key components of a robust ejection system include:

  • Hydraulic cylinders with manifolded hydraulic lines and standard cylinder sub-assemblies for easy replacement
  • Pneumatic cylinders with internally balanced air lines for even actuation
  • Rocker arms that are fully hardened to provide extended life, and configured to meet the stroke and dwell requirements of the application
  • Oversized Alignment Components - Their use is recommended in any mold base because of the following benefits:
  • Tight toleranced leader pins and bushings to improve longevity and reduce wear on more delicate mold surface components
  • Hardened taperlocks and straight-side interlocks to ensure accurate parting line alignment and consistent molded parts

Machining mold base plates exclusively from stainless steel extends plate life and reduces maintenance. Precision jigboring ensures all critical machining is accurately positioned and sized, even on the largest mold base plates.

Providing engineering resources throughout each project and working closely with molders and mold makers ensures that mold base integration is fast and simple. A complete mold base project should include:

  • Reviewing specific application and proposed insert concepts
  • Reviewing machine and facilities that will accept the mold base
  • Design review of the final mold base system, its functionality, and installation requirements
  • Assembly and test of the mold base
  • Shipment of the mold base to the mold maker for installation of inserts
  • Field assistance with start up, preventative maintenance, and global spare parts support

Innovative design, tight tolerance machining, and robust componentry are crucial for the demanding, high-output environments of today's molding operations. For example, a Husky Injection Molding Systems customer using a 2x64 mold base (see image) with rotating ratchet ring unscrewing technology has run more than 10 million cycles in the past 5 years with minimal down time. The customer only conducts preventative maintenance every 6 to 8 months, as opposed to every 6 to 8 weeks with conventional rotary core molds.

This information is provided by Husky Injection Molding Systems Ltd. (Bolton, Ontario, Canada).

 

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