No matter your consulting needs at BHC Associates we have you covered. Renowned throughout North America, our firm brings together world class injection molding experts. We have gained a reputation as a proud and trusted provider of injection molding services through proven results, unmatched expertise, and quality customer service.
Mold Design and Mold Making
BHC Associates
Choosing the right mold
Deciding on a mold design, mold construction material, and manufacture method are crucial aspects that will determine the success of you injection molding operations and the quality of your molded parts. With so many aspects to consider choosing the right mold for your productions can be daunting. We can help! We have a highly experienced team dedicated to the design and manufacture of molds for plastics injection molding. The truth is that every manufacturer of injection molded parts will have a different idea of what the right mold will look like. Some might need highly durable molds for high volume production others may need highly detailed molds or molds that can produce complex shapes. There are a lot of variables to consider so read on and learn what our team can do for you.
Deciding on a mold design, mold construction material, and manufacture method are crucial aspects that will determine the success of you injection molding operations and the quality of your molded parts. With so many aspects to consider choosing the right mold for your productions can be daunting. We can help! We have a highly experienced team dedicated to the design and manufacture of molds for plastics injection molding. The truth is that every manufacturer of injection molded parts will have a different idea of what the right mold will look like. Some might need highly durable molds for high volume production others may need highly detailed molds or molds that can produce complex shapes. There are a lot of variables to consider so read on and learn what our team can do for you.
Mold Design
BHC Associates
We have the needed expertise to assist you with the design of your mold. The mold is the most important and most expensive component of the entire process. From the initial design stage there is very little room for error. There are various different parts to keep in mind during the design process these include the parting line, runners, and the gates. Shrinkage values and many other specifications must also be considered to avoid costly mistakes .Design flaws in any of these areas could mean a costly redesign, but not to worry our firm uses cutting edge design methods to eliminate errors and ensure superb results. We take a holistic approach to designing molds and during the design process we carry out several analyses and follow strict protocols to ensure that the mold is ready for construction, these protocols may include:
We employ a rigorous design for manufacture process to optimize and refine the mold design and to lower manufacturing costs. We refine each part of the mold design with the goal of making the highest quality mold at the lowest possible cost. The analyses we carry out during this process may include:
Mold Flow Analysis for Mold design
To ensure the best possible results we run a Moldflow analysis simulation to evaluate the mold design and further enhance it. We want to ensure that the mold can be built successfully. The simulation allows us to refine injection parameters, determine and optimize cycle times, determine optimal gate location, analyze cooling system, improve welding lines and much more. This is a crucial step in our design process that gives us excellent insights and allows us to build the best possible mold the first time around.
Mold Design Simulation
We simulate the mold design using state of the art CAD software. Through this analysis we can see exactly what the mold will look like once it is produced. We analyze its dimensions and make sure the mold model is built and optimized according to the standards laid out in the design for manufacture report. There are several different design programs and each provide differing benefits, our experts are familiar with any and all design programs including but not limited to Auto CAD, Mastercam ,Unigraphics NX, Pro-Engineer, Auto Desk Moldflow, Solidworks, and Powermill.
3D Printing Mold Prototype
After the design is fully optimized, we 3D print a mold prototype. This will allow us to analyze the actual- sized mold to ensure that the finished product is of high quality and the mold is accurate and ready for construction. Our firm has state of the art rapid prototyping capabilities and we can print a working prototype in a matter of hours to a few days. Aside from design validation 3D printing the mold is a fast and affordable way to uncover hidden issues before we start production of the final mold. This step is meant to avoid costly redesign issues that can happen further down the line. What's more, some 3D printed mold prototypes can even be used to test production of injection molded parts at low volumes. And if needed, several different iterations of the mold can be quickly printed and tested, allowing us to compare the advantages of different mold designs.
Final Material Selection
Once we have validated a working prototype of the mold. We can start determining the optimal mode of construction and the material. The three most common materials for mold construction are hardened or pre-hardened steel, aluminum, and/or beryllium-copper alloy. The strongest most durable molds are usually made from hardened or pre-hardened steel. Of course, given their durability steel molds are more expensive when compared to aluminum or beryllium-copper alloy. But the upside is that steel molds can be used for high volume production and are able to produce well over a million parts during their lifetime. Hardened steel molds offer superior wear resistance and lifespan when compared to pre-hardened steel or other materials. Pre-hardened steel molds are less wear resistant but they are also more affordable. On the other hand, aluminum molds are much more affordable but they are not optimal for high volume production and they will have a difficult time producing molded products with narrow dimensional tolerances. Aluminum molds are still a great option nonetheless, as they are still able to reliably produce tens of thousands to hundreds of thousands of parts during their lifetime. Copper alloy is most commonly used in certain parts of the mold for fast heat removal. Using copper alloy in this manner can improve cycle times in some circumstances. There are many things to consider when selecting the appropriate material for your needs. If you have further questions, feel free to contact us.
- Plan for mold concept
- Create 2D design drawings
- Create 3D CAD model using state of the art software
- Design for Manufacture analysis
- Analyze and confirm mold design
- Analyze mold design specifications
- Optimize mold design
We employ a rigorous design for manufacture process to optimize and refine the mold design and to lower manufacturing costs. We refine each part of the mold design with the goal of making the highest quality mold at the lowest possible cost. The analyses we carry out during this process may include:
- Sink Mark analysis
- Material analysis
- Shrinkage analysis
- Part dimensions and weight analysis
- Parting line analysis
- Mold base analysis
- Insert line analysis
- Analysis of slide and retractor lines
- Ejector analysis
- Gates analysis
- Mold layout analysis
Mold Flow Analysis for Mold design
To ensure the best possible results we run a Moldflow analysis simulation to evaluate the mold design and further enhance it. We want to ensure that the mold can be built successfully. The simulation allows us to refine injection parameters, determine and optimize cycle times, determine optimal gate location, analyze cooling system, improve welding lines and much more. This is a crucial step in our design process that gives us excellent insights and allows us to build the best possible mold the first time around.
Mold Design Simulation
We simulate the mold design using state of the art CAD software. Through this analysis we can see exactly what the mold will look like once it is produced. We analyze its dimensions and make sure the mold model is built and optimized according to the standards laid out in the design for manufacture report. There are several different design programs and each provide differing benefits, our experts are familiar with any and all design programs including but not limited to Auto CAD, Mastercam ,Unigraphics NX, Pro-Engineer, Auto Desk Moldflow, Solidworks, and Powermill.
3D Printing Mold Prototype
After the design is fully optimized, we 3D print a mold prototype. This will allow us to analyze the actual- sized mold to ensure that the finished product is of high quality and the mold is accurate and ready for construction. Our firm has state of the art rapid prototyping capabilities and we can print a working prototype in a matter of hours to a few days. Aside from design validation 3D printing the mold is a fast and affordable way to uncover hidden issues before we start production of the final mold. This step is meant to avoid costly redesign issues that can happen further down the line. What's more, some 3D printed mold prototypes can even be used to test production of injection molded parts at low volumes. And if needed, several different iterations of the mold can be quickly printed and tested, allowing us to compare the advantages of different mold designs.
Final Material Selection
Once we have validated a working prototype of the mold. We can start determining the optimal mode of construction and the material. The three most common materials for mold construction are hardened or pre-hardened steel, aluminum, and/or beryllium-copper alloy. The strongest most durable molds are usually made from hardened or pre-hardened steel. Of course, given their durability steel molds are more expensive when compared to aluminum or beryllium-copper alloy. But the upside is that steel molds can be used for high volume production and are able to produce well over a million parts during their lifetime. Hardened steel molds offer superior wear resistance and lifespan when compared to pre-hardened steel or other materials. Pre-hardened steel molds are less wear resistant but they are also more affordable. On the other hand, aluminum molds are much more affordable but they are not optimal for high volume production and they will have a difficult time producing molded products with narrow dimensional tolerances. Aluminum molds are still a great option nonetheless, as they are still able to reliably produce tens of thousands to hundreds of thousands of parts during their lifetime. Copper alloy is most commonly used in certain parts of the mold for fast heat removal. Using copper alloy in this manner can improve cycle times in some circumstances. There are many things to consider when selecting the appropriate material for your needs. If you have further questions, feel free to contact us.
Mold Construction
BHC Associates
At BHC Associates we employ cutting edge mold construction methods that ensure the highest quality build for your mold. We specialize in computer numerical control machining (CNC) and Electrical discharge machining (EDM). We use industry leading CNC and EDM equipment to build your mold under extremely tight tolerances.
CNC Machining
Our cutting-edge CNC equipment works by first defining the mold’s mechanical dimensions as reported by the model created in our CAD software. Then our CAM Program determines the manufacturing procedures and lastly our post process program follows these instructions and creates commands for the CNC machine. The CNC machine then starts working on the mold step by step. The entire process is monitored by our experts to ensure efficiency and high-quality mold construction.
Electric Discharge Machining (EDM)
Our Leading edge EDM equipment works by shaping the mold using a specialized electrode and a controlled electrical charge. The spark gap between the electrode and the mold is maintained at a few thousands of an inch. The mold must be submerged in dielectric liquid in order for the process to work effectively. This process is sometimes slower than CNC machining, but there are some unique advantages to using EDM, mainly that EDM is able to produce a greater variety of shapes. However, there is also the benefit of not having to heat treat pre-hardened molds after EDM.
Mold Surface Textures
We are also able to modify the mold surface finish. By modifying the surface finish, it is possible to achieve several different textures. The surface finish or texture of the mold will have a direct effect on the surface texture of the molded plastic parts that are produced with that particular mold. Therefore, in many cases it may be necessary create a specific surface finish or texture on the mold. We can create many different textures through CNC, ground, EDM, acid etching, and laser engraving. There are many textures to choose from. If you have further questions about mold surface finishes. Contact our team.
Superior Expertise and Competitive Prices
Our expert mold makers have over 35 years of experience designing and producing molds and thanks to our highly efficient manufacturing capabilities and superior expertise we are able to produce molds in just a few business days. Our superior expertise also allows us to offer the highest degree of customization for your mold. What's more, we offer competitive pricing on your custom-built mold. Contact us for more information on pricing and mold customization.
Trust Industry Leading Experts
Trust industry leading experts with your mold design and manufacture project. Our team’s expertise is unmatched in the industry. With well over a 100 years of combined experience our team’s expansive knowledge and expertise has gained us a reputation as a leading and trusted provider of injection molding services.
CNC Machining
Our cutting-edge CNC equipment works by first defining the mold’s mechanical dimensions as reported by the model created in our CAD software. Then our CAM Program determines the manufacturing procedures and lastly our post process program follows these instructions and creates commands for the CNC machine. The CNC machine then starts working on the mold step by step. The entire process is monitored by our experts to ensure efficiency and high-quality mold construction.
Electric Discharge Machining (EDM)
Our Leading edge EDM equipment works by shaping the mold using a specialized electrode and a controlled electrical charge. The spark gap between the electrode and the mold is maintained at a few thousands of an inch. The mold must be submerged in dielectric liquid in order for the process to work effectively. This process is sometimes slower than CNC machining, but there are some unique advantages to using EDM, mainly that EDM is able to produce a greater variety of shapes. However, there is also the benefit of not having to heat treat pre-hardened molds after EDM.
Mold Surface Textures
We are also able to modify the mold surface finish. By modifying the surface finish, it is possible to achieve several different textures. The surface finish or texture of the mold will have a direct effect on the surface texture of the molded plastic parts that are produced with that particular mold. Therefore, in many cases it may be necessary create a specific surface finish or texture on the mold. We can create many different textures through CNC, ground, EDM, acid etching, and laser engraving. There are many textures to choose from. If you have further questions about mold surface finishes. Contact our team.
Superior Expertise and Competitive Prices
Our expert mold makers have over 35 years of experience designing and producing molds and thanks to our highly efficient manufacturing capabilities and superior expertise we are able to produce molds in just a few business days. Our superior expertise also allows us to offer the highest degree of customization for your mold. What's more, we offer competitive pricing on your custom-built mold. Contact us for more information on pricing and mold customization.
Trust Industry Leading Experts
Trust industry leading experts with your mold design and manufacture project. Our team’s expertise is unmatched in the industry. With well over a 100 years of combined experience our team’s expansive knowledge and expertise has gained us a reputation as a leading and trusted provider of injection molding services.
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