This year, ACO Mold plastic injection molding manufacturer made a set of plastic injection mold for a company from Brazil. The Brazil company works on manufacturing equipment for industrial climbing. The injection molded part is plastic handle enclosure, and the material is PA6+50%GF.

Basic part information

• Part size: 27.589 X 40.541 X 11.389/ 167.122 X 75.755 X 26.000/ 70.584 X 91.930 X 24.300mm
• Plastic material: PA6+50%GF
• Finish: SPI-B1
• Color: Black
• Production volume: 5K

Basic mold information

• Mold type: 2-Plate
• Gate type: Side Gate
• Cavity number: 1+1+1
• Material: PA6+50%GF
• Shrinkage: 1.005

Usually, ACO Mold will do DFM before mold design and mold manufacturing. Once customer make tooling deposit, we work on DFM immediately.

The DFM showed how’s the parting line, gating method, ejection etc of the injection mold. Then DFM was sent to customer for comments. Regarding the draft angle, we added it and updated the part drawings based on customer’s comments on DFM.
About wall thickness, the wall thickness of red area is heavy, will risk of sink marks, so ACO Mold proposed to reduce the material for it.

Then we designed the mold in 3D, and ordered steel and mold base for mold making. During injection mold manufacturing, we regularly reported mold making progress, such as steel cutting, CNC rough machining etc via sending pictures or videos.

After injection mold manufacturing was done, we did T1 sampling. Then T1 samples were shipped to Brazil for comments. There are a few appearance problems on the samples. We sent PPT to show them. After customer checked the assembly and function, and made the comments, so we can improve all problems together at T2 sampling.

Besides the appearance problems, customer is satisfied with these samples. So we just arranged to modify the mold for the mismatch and burrs problem. Large volume plastic injection molding was approved by customer, and the appearance problem was solved in mass production of injection molded plastic parts.