Dec. 02, 2024
Precision injection molding demands attention to several critical factors that directly influence the quality, accuracy, and reliability of the final product.
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Let&#;s break down some of these essential considerations.
The mold itself is one of the most vital components in precision injection molding.
Its design and construction must ensure dimensional accuracy and high durability to withstand the repeated forces involved in molding.
Key factors include:
Selecting the right plastic or polymer is crucial in achieving tight tolerances and dimensional stability.
Precision molding often relies on materials with low shrinkage rates to maintain accurate part dimensions.
Common choices include:
Precision injection molding requires advanced machinery capable of delivering consistent results under stringent conditions.
Here are the machine attributes that impact precision:
Precision injection molding relies on the synergy between mold design, material choice, and machine capability.
By carefully managing these factors, manufacturers can achieve the high accuracy and repeatability essential for producing complex, high-quality parts.
Precision injection molding requires careful management of challenges like shrinkage, dimensional stability, and repeatability to achieve consistent, high-quality parts.
Let&#;s look at these issues and effective solutions for each.
Shrinkage and warping can distort part dimensions, impacting accuracy.
To manage these issues:
Dimensional stability is crucial to ensuring that each part meets strict tolerances.
Factors that support stability include:
Achieving identical parts over long production runs is a cornerstone of precision injection molding.
Solutions to improve repeatability include:
Effectively addressing these common challenges through advanced controls and rigorous quality checks ensures that precision injection molding yields parts that are accurate, stable, and repeatable, meeting stringent standards across industries.
Selecting the right materials for precision injection molding is essential to achieving tight tolerances and dimensional stability.
Here, we look at polymers known for their low shrinkage properties and how fillers and additives further enhance material performance.
For precision applications, materials with low shrinkage rates are critical to maintaining the dimensional accuracy of parts.
Commonly used polymers include:
Each of these polymers offers unique properties, allowing manufacturers to match materials to specific requirements, from heat resistance to flexibility and mechanical strength.
Incorporating fillers and additives into base polymers further optimize material properties, particularly for reducing shrinkage and improving dimensional stability:
The combination of low-shrinkage polymers and strategic fillers ensures that precision-molded parts meet strict tolerances and maintain their integrity throughout their lifecycle.
By carefully selecting materials, manufacturers can address unique project needs and achieve reliable results in high-precision applications.
Precision injection molding requires specialized machinery equipped with advanced features to ensure every component meets tight tolerances and high-quality standards.
Here&#;s what makes precision molding machines distinct:
Precision injection molding machines must meet stringent requirements to achieve the accuracy and repeatability essential for high-precision parts:
Closed-loop control systems are essential in precision molding for maintaining consistent temperature, flow, and pressure throughout the process.
These systems use sensors to monitor conditions in real time, instantly adjusting any fluctuations to keep the process stable.
This ensures the final product meets exact specifications, reducing variability and improving repeatability.
Automation plays a key role in precision injection molding, especially for high-volume production runs where quality consistency is crucial.
Automated systems allow for:
Precision injection molding machines with advanced control systems and automation are designed to deliver the accuracy, repeatability, and efficiency needed for the exacting demands of high-precision components across industries like automotive, medical, and electronics.
Maintaining high standards in precision injection molding is critical for producing parts that consistently meet strict specifications.
Here&#;s how quality control is implemented to ensure every part meets those exacting standards:
Precision molding demands rigorous quality checks, utilizing advanced technology to detect and rectify defects early in the process.
Some primary methods include:
Coordinate Measuring Machines (CMM): CMMs are essential for measuring complex part geometries with high precision. By scanning dimensions in real time, CMMs help confirm that each component meets design specifications down to the smallest detail.
Optical Inspection Systems: Optical inspection systems enable non-contact measurement of parts. They capture detailed surface profiles, checking for uniformity and catching imperfections such as warping or dimensional variances that might otherwise go unnoticed.
Regular Mold Maintenance: Precision molding molds must be kept in peak condition to ensure quality. Routine cleaning, realignment, and inspections of the molds prevent wear-induced defects and maintain tight tolerances. This minimizes the risk of errors and ensures the longevity of the molds.
While automation handles many aspects of quality control, skilled operators play an essential role in managing the process and ensuring consistent quality:
Monitoring and Adjustment: Experienced operators are trained to monitor production closely, spotting issues that automated systems might miss. They adjust machine settings, such as temperature, injection pressure, and cycle times, based on part requirements and material properties.
Troubleshooting and Problem Solving: Skilled operators excel at diagnosing and resolving production issues, from minor adjustments to larger issues like equipment malfunctions. Their expertise ensures that production remains smooth and that any irregularities are swiftly addressed, preventing costly downtime and maintaining part quality.
Effective quality control in precision injection molding combines advanced inspection tools with the experience of skilled operators, ensuring each part meets the highest standards in accuracy, functionality, and durability.
Precision injection molding serves as a cornerstone for industries requiring parts with high accuracy and strict tolerances.
Let&#;s explore some of the key industries that rely on precision injection molding and the typical products they produce:
Precision injection molding is essential across multiple sectors, offering the accuracy and consistency needed for high-performance applications:
Medical Industry: Medical devices and tools require extreme accuracy, especially for parts used in surgical equipment, diagnostic devices, and implantable components. Precision molding enables the production of complex shapes with consistent quality, ensuring reliability and safety in medical applications.
Automotive Industry: The automotive sector benefits from precision molding for components like fuel injection systems, sensors, and electronic connectors. High tolerance levels ensure these parts perform well under stress and harsh environments, which is essential for vehicle safety and efficiency.
Electronics and IT: In the electronics sector, precision molding supports products with tight geometric requirements, such as circuit board connectors, switches, and housing for delicate components. This industry demands high-quality molding for longevity and performance in high-stress applications.
Aerospace and Defense: Aerospace components, such as connectors, casings, and sensor housing, require precise dimensional stability. Precision molding provides the resilience and lightweight construction necessary for aerospace applications, where reliability and performance are paramount.
Each of these industries relies on precision injection molding for products that meet exact specifications:
Medical Devices: Surgical instruments, syringe components, and intricate parts for diagnostic equipment are all made using precision molding, which ensures consistent and safe usage.
Automotive Sensors and Connectors: Fuel injectors, sensor housings, and various connectors need precise dimensions to ensure functionality and safety in automotive systems.
Electronic Components: Circuit board connectors, micro-switches, and housing for processors benefit from precision molding, which provides protection and durability for sensitive components.
Optical Lenses and Components: High-precision molding is instrumental in creating lenses and other optical components that require smooth surfaces and minimal distortion for maximum clarity.
Precision injection molding enables the production of intricate parts for these sectors, where consistency, accuracy, and durability are critical for meeting industry standards and regulatory requirements.
Choosing a precision injection molding partner is crucial for ensuring high-quality parts that meet your project&#;s exact requirements.
Here&#;s what to look for in a manufacturing partner:
When selecting a precision injection molding partner, consider these essential criteria:
Expertise and Experience: A reliable partner should have extensive experience in precision molding and a proven track record of successful projects, especially in your industry. This expertise helps ensure they can navigate the complexities of precision molding to achieve high-quality results.
Technological Capabilities: Advanced molding technology, such as high-precision molds, closed-loop systems, and automated controls, is vital for producing accurate and repeatable parts. Look for a manufacturer with up-to-date equipment that can meet your specific tolerances and production demands.
Quality Control Measures: A trustworthy partner should have strict quality control protocols, including coordinate measuring machines (CMMs) and optical inspection systems. Consistent monitoring of each production stage ensures the final parts meet the required standards without deviations.
Customer Support: Excellent customer support is essential, from the initial consultation to the delivery of finished parts. The manufacturer should offer clear communication, technical support, and timely updates throughout the production process.
Every precision molding project has unique specifications, from material selection to mold design and final tolerances.
Choose a manufacturer that offers customized solutions to align with your project&#;s specific requirements:
Process Adaptability: Ensure the partner can adjust key parameters, such as injection pressure, cycle time, and cooling rates, to accommodate complex part geometries and materials.
Mold Design Expertise: Look for a partner skilled in designing precision molds that match your part&#;s exact dimensions and tolerances. This includes optimizing mold design for minimal shrinkage, proper gating, and efficient cooling.
With the right precision injection molding partner, you gain a trusted collaborator who can not only produce high-quality parts but also streamline your production, ensuring each piece meets your specific standards.
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employs a team of approximately 20 highly skilled professionals, including moldmakers, engineers, designers, machinists and apprentices. Source (All images) | Molded Precision Components and MPC Advanced Machining
Darryl Gratrix, Tooling Manager, Molded Precision Components: MPC Advanced Machining is a division of Molded Precision Components (MPC) that specializes in high-precision mold building and CNC machining services. This Division has been operating for several years as part of the broader MPC company, which has a rich history dating back to its founding in . It has been under the current ownership since .
MPC Advanced Machining operates out of a state-of-the-art facility that spans over 70,000-square-feet. The two facilities are located at 165 and 239 4th Line South, Oro-Medonte, Ontario, Canada. Included are engineering offices, metrology and inspection labs and two machine shops. The facility is equipped with cutting-edge technology and advanced machinery, including high-speed (CNC machine centers (42,000 rpm), wire and sink CNC EDM and precision grinding from suppliers such as GF Machining Solutions, System 3R and Mitutoyo.
The division employs a team of approximately 20 highly skilled professionals, including moldmakers, engineers, designers, machinists and apprentices. The entire MPC company has a workforce of around 85 employees with a significant portion dedicated to the machining division. We currently have one moldmaker apprentice, two machinist apprentices and one millwright apprentice.
This team is involved in the design, development and maintenance of high-precision molds, including multi-cavity and complex molds used in various industries such as automotive, medical and consumer goods. We specialize in producing molds and molded parts for the most demanding applications, most often tight tolerance and functionally critical parts such as gears, housings and fittings. We produce some highly complex molds requiring insert molding and over molding.
MPC Advanced Machining specializes in manufacturing molds and molded parts for the most demanding applications, most often tight tolerance and functionally critical parts like this innovative cube mold technology that enables multi-material injection and efficient high-volume production through synchronized rotation.
We build complex multi-cavity molds, including sophisticated tool actions, rotary cores, hot runner systems, valve gates and three-plate tools. We also have developed gear tooling technology to make all types of precision gears including worm, helical, spur, sector and internal gears. We can design and build molds with up to 32 cavities.
This division offers various machining services, including CNC milling, turning, wire and sinker EDM, precision grinding and mold assembly. We also offer inspection, measurement and reverse-engineering services including CMM, 3D blue-light scanning and highly detailed reporting. Last but not least, we provide mold repair, maintenance and engineering support to ensure that molds operate at peak efficiency.
165 Line 4S, Shanty Bay, Ontario, Canada L0L 2L0
705- 487- / 877- 487-
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mpccomponents.com/ mpccomponents.com/services mpccomponents.com/capabilities/tooling-precision-machining/
Gratrix: Our chief competitive advantage lies in our ability to deliver highly precise and complex machining solutions, supported by a team of skilled professionals and state-of-the-art technology. However, other shops have similar equipment, so our main edge comes from the processes and systems we have implemented to fully utilize this equipment, often achieving better results than what the manufacturer advertises.
For example, we program and set up our FORM200 sinker EDM using Cimatron&#;s EDM package, unlike most companies that still do it manually, which can lead to numerous data entry errors. We measure 100% of our electrodes on our tool room CMM and then transfer all the offsets electronically to the sinker EDM using software developed by our CMM programmer/operator.
CNC milling and sinker EDM machines use multi-pallet automation with robotic tending to run parts fully unattended. This technological shift has allowed MPC Advanced Machining to reduce lead times, improve consistency and take on more complex projects with greater accuracy.
We also have team members in the tool room and engineering department who do computer programming as a hobby. We have been able to harness their passion for programming and align it with our company's needs. On top of that, we have employees who are more satisfied with their jobs because they&#;re able to combine their passion with their work. All of this enables us to consistently meet the rigorous standards of industries like automotive and medical, ensuring exceptional quality and reliability in every project.
Gratrix: In the past two years, we have adopted advanced automation and robotics in our machining processes, significantly enhancing production efficiency and precision. Our CNC milling and sinker EDM machines are now using multi-pallet automation with robotic tending to allow us to run parts fully unattended. This technological shift has allowed us to reduce lead times, improve consistency and take on more complex projects with greater accuracy.
Key machines in our facility include a GF FORM200 sinker EDM, GF Mikron HSM500, 3R WorkPartner automation unit between a FORM200 and HSM500 and a Mitutoyo Stratos 540 CMM. Key software includes Cimatron-Electrode design, sinker EDM programming, milling CAD/CAM, Solidworks-Design, Esprit for wire EDM programming and various MPC-developed programs. This software implementation has helped increase our throughput. Our record for setting up electrodes in one day is 70, which is considered impressive for those familiar with sinker EDM.
&#;But it&#;s really the smiles on the faces of the employees that is the biggest change. That&#;s honestly the thing I&#;m most proud of in our toolroom. Over my 11 years here at MPC, the culture change has been remarkable.&#;
Gratrix: In the past two years, we have strategically focused on expanding our services beyond internal projects by actively attracting outside business. This shift began with establishing MPC Advanced Machining as a dedicated division, allowing us to leverage our high-precision capabilities and industry expertise to serve a broader range of customers and industries.
In July , we implemented ProShop as our tool room ERP software, improving our operations through efficiency, automation and real-time data access. This paperless system streamlines everything from quoting and scheduling to production tracking and quality management, minimizing manual input and reducing errors. With real-time visibility into production processes and equipment use, we can quickly adapt, reduce downtime and make data-driven decisions. Its quality management tools ensure we consistently deliver high-precision products and the customizable and scalable features support our growth, ensuring optimized processes as capabilities expand, particularly with our cube technology.
The company motto is simple: &#;Our purpose isn&#;t just to make plastic parts &#; it&#;s to create a workplace where people are treated well and can thrive.&#;
But it&#;s really the smiles on the faces of the employees that is the biggest change. Honestly, that&#;s the thing I&#;m most proud of in our tool room. Over my 11 years here at MPC, the culture change has been remarkable. The team genuinely enjoys coming to work now, and we have fun working together. What&#;s even more exciting is that we&#;ve recently been able to extend that positive culture to our relationship with the engineering department, which has historically been a challenge in most manufacturing environments. As we all know, the tension between tool rooms and engineering is pretty infamous, but we&#;ve broken down those barriers. Now we&#;re working more closely and effectively than ever.
When joining MPC, the company aimed to create a unique culture, different from typical manufacturing environments. However, some initial behaviors contradicted this vision, particularly within team interactions. Leadership acknowledged that achieving the ideal culture was a work in progress and took steps to address the issues. With a focus on leading by example and creating a respectful environment, efforts to promote positive change became more effective. Over time, changes in leadership and addressing toxic behaviors contributed to a healthier and more collaborative workplace culture. We're not perfect, but we&#;ve built a team that enjoys working together. While differences remain, especially between older toolmakers and younger engineers, I emphasize the importance of mentoring. Our experienced team is responsible for guiding and training the next generation, which helps strengthen collaboration across departments.
One of my proudest moments was hearing a student say MPC stood out because our employees were happy and engaged, unlike other shops. Our owner&#;s belief is simple: our purpose isn&#;t just to make plastic parts &#; it&#;s to create a workplace where people are treated well and can thrive.
Gratrix: MPC is addressing the skills gap by partnering with the Simcoe County District School Board and the Simcoe Muskoka Catholic School Board, and participating in the Ontario Youth Apprenticeship Program (OYAP). This initiative allows high school students to begin their apprenticeship training in skilled trades while earning their diplomas. We offer Advanced OYAP for Precision Metal Skills, where students complete a co-op during their final semester of high school and start their Level 1 apprenticeship schooling at Georgian College. This gives them a significant advantage by finishing Level 1 and gaining about 1,000 apprenticeship hours before graduating.
&#;Our main edge comes from the processes and systems we have implemented to fully utilize our equipment, often achieving better results than what the manufacturer advertises.&#;
We also host tours for high school guidance counselors to introduce them to modern manufacturing. Many are surprised by how clean and advanced our facility is, and we're now part of the field trip roster for Simcoe County high schools. I also participate in professional development events for high school teachers to promote skilled trades education and clarify employer expectations.
One of my personal goals is to introduce two to three weeks of skilled trades curriculum into Ontario&#;s mandatory Grade 10 careers course. This would ensure all students are informed about the opportunities in trades.
MPC also participates in local events like the LEVEL UP skilled trades open house and the Ontario Apprenticeship Summit. We maintain a strong relationship with Georgian College, where 23 of our 75 employees are graduates, and I serve on the Program Advisory Committee for Precision Skills to help ensure the program produces competent graduates.
We actively promote careers in skilled trades through community outreach and social media, emphasizing the rewarding opportunities in machining to attract and develop the next generation of skilled professionals.
The experienced team at MPC guides and trains the next generation of moldmaking professionals and helps to improve cross-departmental collaboration.
Gratrix: We have implemented a robust apprenticeship and training program, partnering with local schools and industry organizations to nurture talent from the ground up. Our apprenticeship and training program is designed to develop skilled trades professionals through hands-on experience, mentorship and structured learning.
Six key aspects of the program are:
Cube technology improves injection molding by providing enhanced precision and consistency, enabling the production of complex geometries with greater efficiency and reduced cycle times, ultimately leading to higher-quality molded parts and increased productivity.
Gratrix: We were awarded a notable project involving the development and implementation of innovative cube mold technology for the automotive industry. The cube technology offers significant advantages to customers by allowing multi-material and multi-component injection molding in a single cycle. This approach results in faster production times, increased efficiency and lower costs by consolidating multiple processes into one machine cycle. The cube mold rotates between different stations, enabling simultaneous injection of different materials or colors, overmolding or even the production of two different parts at once.
This technology is especially beneficial for high-volume production, as it reduces the need for secondary operations and increases overall throughput, ensuring faster delivery of high-quality, complex parts. Customers in industries such as automotive, medical devices and consumer products benefit from improved product design flexibility, reduced lead times and enhanced cost-effectiveness.
One particular project required the design and manufacture of a highly efficient cube mold system capable of producing multiple parts simultaneously, significantly reducing cycle times and increasing production efficiency. The success of this project showcased our ability to deliver cutting-edge solutions that meet the demands of high-volume production environments, further establishing the company as a leader in advanced tooling and manufacturing technologies.
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