Key Components To Look For With Precision Casting

Precision casting is a casting method with a very long history. In Ancient Egypt and China, people used beeswax patterns to create jewelry and other items that could have precise shapes and lines and could also be effectively recreated. People have always appreciated the efficiency and ease of creating parts from molds throughout ancient history to modern times.

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Today, the process has become more technical than beeswax molds and is capable of creating much more than jewelry, but the principle is the same: a casting process that can create precise, high-quality materials. Not all casting companies or processes are the same, so it&#;s important to know exactly who you&#;re going into business with and what their standards are before beginning a major project with them. When you&#;re looking for a precision casting company to work with, make sure you&#;re working with a team that can offer you all of the following benefits.

Quality and Repeatability

Using casting technology means you should be able to expect precise materials that are repeatable. You should be able to use these molds to make identical items as many times as you need to, and you should be able to expect the exact same features and physical aspects every time this item is made. But just because something is easy to duplicate doesn&#;t mean it has to lack in quality. 

Everything made from your precision casting method should be dependably high quality; every identical piece should meet your needs exactly as well as the next piece. Our own company is the only ISO Certified copper-based permanent mold facility in North America, which means we are held to strict quality control guidelines and high standards.

Pacing and Speed

Just because precision casting can be slow doesn&#;t mean it should be. With the right company, each project can run as a complete operation, rather than becoming a slow-moving batch project. Find a company that keeps your project in constant motion, from tooling to finishing, and you&#;ll find that the amount of time the entire process takes will drop considerably. Some companies will focus on each process independently, which often means your materials are sitting in a dead zone for long stretches at a time. 

Find a company that uses a consecutive process instead. Our own machining and plating services are done at our foundry, which will save you time and reduce your shipping costs simultaneously. Make sure to ask questions before you commit to a precision casting company so that you know exactly how their product line works and what kind of timeframe they can offer you on your materials.

Affordability

It&#;s obvious that you need your precision casting process to be affordable, but don&#;t ever sacrifice quality in the name of saving a few dollars. Look for a company that can explain their process and costs in a way that makes sense; costs shouldn&#;t seem dramatically out of line in either direction with the amount of effort that goes into the overall process. Don&#;t hesitate to ask for an explanation if things don&#;t seem to match up. 

For example, our company uses near-net shape, which means we can produce high quality parts with minimal machining. This process will not only save you money, but will make sure you&#;re receiving the highest possible quality items as well. No matter what kind of project you&#;re working on, we believe that you should be able to get the high-quality parts you need for a fair price.

The Takeaway

Don&#;t settle for anything less than what you need when you&#;re looking for a precision casting company to work with. You can, and should, find a company that can offer you completely identical and dependable high-quality parts that are produced quickly and affordably without sacrificing quality. If you aren&#;t fully satisfied with what your current precision casting company can do for you, shop around until you are satisfied.

You can get a free quote for a bulk order from us today to learn more about the kind of services we offer and what they can do for you. We&#;ll be in contact within 24 hours to answer any questions you might have. We&#;re confident that you&#;ll be impressed with the quality, timeliness and affordability we can offer you and your project.

Obtaining an accurate injection molding quote is crucial for the success of your manufacturing project. A well-executed quote provides essential insights into your project&#;s cost, feasibility, and timeline, allowing you to make informed decisions and ensure a smooth manufacturing process.

However, to obtain an accurate quote, it is essential to consider several critical questions before approaching a manufacturer.

In this blog post, we will guide you through eight vital questions that you should consider before getting an injection molding quote.

By addressing these questions upfront, you can enhance the clarity and effectiveness of your communication with potential manufacturers, leading to more accurate and tailored quotes for your project.

Let&#;s delve into these eight questions and explore how they contribute to a comprehensive understanding of your injection molding project.

1. Are There CAD Drawings, Prints, or Samples of the Part to Be Quoted?

Before you obtain an injection molding quote, it is crucial to assess the availability of CAD drawings, prints, or samples related to the specific part you intend to manufacture. These valuable resources are vital in ensuring a smooth and accurate quoting process.

For instance, a study titled &#;Soft lithography for micro- and nanoscale patterning&#; by Qin, Xia, and Whitesides () emphasizes the importance of detailed visual representation in manufacturing processes.

CAD Drawings

Having detailed CAD (Computer-Aided Design) drawings of your part is highly advantageous when seeking an injection molding quote.

CAD drawings also help evaluate potential design modifications and optimize the manufacturing process for cost efficiency and quality.

Prints

Prints offer a two-dimensional representation of the part, complete with measurements and notes. These drawings typically include essential information such as part dimensions, tolerances, surface finishes, and any additional specifications required for manufacturing.

Providing accurate and complete prints can significantly assist the manufacturer in assessing the part&#;s complexity and estimating the time and resources required for its production.

Physical Samples

In some cases, having physical samples of the part can be beneficial during the quoting process. Samples allow the manufacturer to visually inspect and evaluate the part&#;s design, material properties, and potential challenges in manufacturing.

Suppose a manufacturer has a physical sample of a part. In that case, they can thoroughly examine potential challenges, such as undercuts or thin walls, which may impact the mold design or production process.

2. Are You Running the Parts from an Existing Mold?

If you&#;re planning to run parts from an existing mold, check a few things before proceeding.

Firstly, using an existing mold can be a real-time and cost-saver. As pointed out in a scientific study, injection molding is a standard method for creating parts from reinforced thermoplastic materials.

If you&#;ve got a mold ready, you can skip the design and fabrication stages, speeding up the whole process.

But it&#;s not just about speed. You also need to think about whether the mold you have is suitable for the job. As Elham Sharifi and her team found in their research, traditional injection molding isn&#;t always the best fit, especially for smaller production runs.

If your existing mold isn&#;t up to the task, it might be worth exploring other manufacturing methods.

And let&#;s not forget about the potential of recycled materials. According to a study by Peter E. Caltagirone and his colleagues, recycled fiber can perform just as well as new fiber when it comes to reinforcing materials.

This suggests that recycled fiber could be used in place of new fiber in existing molds.

3. What is the Part Application? Are There Chemical or Environmental Issues the Part Will Be Exposed to?

The part application refers to how and where the part will be used. This could range from automotive components to medical devices, each with unique requirements.

Knowing the part application can help the manufacturer determine the best materials and manufacturing processes.

For example, a part exposed to high temperatures may require a material with high heat resistance. Similarly, a part that will come into contact with corrosive substances may need a material with excellent chemical resistance.

Here are a few questions you should be prepared to answer:

• Will the part be exposed to extreme temperatures, either high or low?
• Will the part come into contact with any corrosive or abrasive substances?
• Is the part intended for indoor or outdoor use?
• Will the part be exposed to moisture or high humidity?
• Will the part be subjected to high stress or impact?
• Does the part need specific properties, such as lightweight or electrically conductive?

Providing this information to the manufacturer at the quoting stage can help ensure the part is fit for purpose and will perform effectively throughout its lifespan.

4. What Quantities Are Needed?

When looking for an injection molding estimate, the quantity of pieces you want is critical information. This assists the manufacturer in determining the most efficient and cost-effective approach to building your parts.

When it comes to producing many parts, injection molding is frequently the best option. This is because, as Jason A. McNulty and his colleagues pointed out in their paper, it is a mass-production technique that can handle enormous volumes.

For more information, please visit Yihua Mould.

But what if you simply require a few parts? In that situation, consider alternatives to injection molding.

According to Haden Edward Quinlan&#;s study, additive manufacturing (AM) can be an intelligent solution for smaller production runs since it can reduce prices and lead times.

For low-volume production, consider 3D printing and CNC machining. These technologies provide greater flexibility and may be set up faster than injection molding.

Here are a few additional things to consider:

• When creating a large number of components, automated quality control methods may be quite beneficial. However, a manual examination may be more feasible if you only make a few.
• The number of parts required might have a significant influence on your prices. When you produce many parts, the cost per unit decreases.

5. What is the Size and Complexity of the Part?

Size of the Part

The part size can influence the type of injection molding machine required. Larger parts typically require larger machines with higher clamping forces to hold the mold closed during the injection.

Additionally, larger parts may require more material and longer cooling times, increasing the cycle time and overall production cost.

• Machine Requirements: Larger parts typically require larger injection molding machines with higher clamping forces.
• Material Usage: Larger parts will require more material, which can increase the cost of production.
• Cooling Time: Larger parts may require longer cooling times, which can increase the cycle time and potentially the cost of production.

Complexity of the Part

The part&#;s complexity refers to its design&#;s intricacy, including features such as undercuts, thin walls, or complex geometries. More complex parts may require advanced mold designs, such as multi-part molds or molds with movable sections.

These complexities can increase the cost of the mold and the time required for mold design and fabrication.

• Mold Design: Complex parts may require more intricate mold designs, which can increase the cost and time required for mold fabrication.
• Molding Considerations: Complex parts may require special molding considerations, such as higher injection pressures or specific cooling strategies, to ensure accurate reproduction of the design and prevent defects.
• Post-processing: Complex parts may require additional post-processing steps, such as finishing or assembly, which can add to the production time and cost.

6. What Types of Polymers or Resins Are Required for the Part?

The type of polymer or resin required for the part is another critical factor when seeking an injection molding quote.

Different polymers and resins have varying properties that can impact the part&#;s performance, durability, and appearance.

Performance in Specific Environments

Different polymers and resins perform differently in various environments. For example, if the part will be used outdoors, a UV-resistant material like polyethylene terephthalate (PET) might be an excellent choice to prevent degradation from sunlight.

Impact on Part Aesthetics

The choice of material can also impact the look and feel of the part. For example, if a glossy finish is desired, a material like acrylonitrile butadiene styrene (ABS) might be suitable. On the other hand, for a matte finish, polypropylene (PP) could be a good choice.

Suitability for Part Complexity

The complexity of the part can also influence the choice of material. For example, if the part has thin walls or intricate details, a material with good flow properties, like polystyrene (PS), might be needed to ensure the material fills the mold properly.

Considerations for Sustainability

If sustainability is a priority, consider using a biodegradable polymer like polylactic acid (PLA) or recycled material. However, these materials may have different properties and costs than traditional polymers and resins.

7. What is the Lead Time?

Lead time refers to the total time required to produce and deliver the parts when the order is placed.

Here are a few factors that can alter the lead time of your project:

• Mold Design Complexity: The complexity of the mold design can significantly impact the lead time. More complex molds take longer to design and fabricate.
• Material Availability: If the required material is not readily available, it may need to be ordered, which can add to the lead time.
• Production Volume: Larger production volumes take longer to manufacture.
• Machinery Availability: If the manufacturer&#;s machinery is fully booked, this can delay the start of production, increasing the lead time.
• Post-Processing Requirements: Any required post-processing steps, such as finishing or assembly, will add to the lead time.
• Quality Control Procedures: Thorough quality control procedures, while crucial, can add to the lead time, especially for larger production volumes.
• Shipping and Logistics: The time required for packing, shipping, and delivery can also add to the lead time, particularly for international shipments or custom delivery requirements.

8. What is the Manufacturing Process?

The manufacturing process outlines the steps and techniques used to create a part.

In the realm of injection molding, this process typically unfolds in the following stages:

1. Design Phase The journey begins with designing the part, usually with CAD software. This design stage considers the part&#;s specific needs, including its size, shape, function, and the material from which it will be made.
2. Mold Fabrication After finalizing the part design, the next step is fabricating a mold. This mold, a hollow container, is filled with molten plastic to shape the part. Precision is key in machining the mold to ensure it aligns with the design and that the final part has the correct dimensions and features.
3. Material Selection and Preparation The next step involves selecting the appropriate polymer or resin based on the part&#;s requirements. The selected material is then prepared for molding, typically heating it until it becomes molten.
4. Injection Molding The molten plastic is injected into the mold under high pressure. After filling the mold, the plastic can cool and solidify, forming the part.
5. Ejection and Post-Processing Once the plastic has cooled, the part is ejected from the mold. Any excess material, referred to as flash, is trimmed off. The part may go through additional post-processing steps, such as painting, assembly, or packaging.
6. Quality Control Quality control measures are implemented throughout manufacturing to ensure the part meets the specified requirements. This may include inspecting the part for defects, measuring its dimensions to confirm they match the design, and testing its performance.

Conclusion

By addressing these eight questions before seeking a quote, you can provide potential manufacturers with the information they need to give you an accurate and tailored quote.

This helps ensure that your project is feasible and cost-effective and will be completed on time and to the highest quality standards.

Remember, every detail matters when it comes to manufacturing. The more information you can provide upfront, the better the outcome.

So, take the time to consider these questions carefully and communicate your needs clearly to your manufacturer.

Get High-Quality Plastic Injection Molding With Kemal

At Kemal, we live and breathe high-quality plastic injection molding. Our industry experts are on a mission to exceed your manufacturing expectations.

From the first quote to the final flawless delivery of your parts, we&#;ve got you covered.

Ready to take your next project to new heights? Contact us today, and let&#;s embark on this manufacturing journey together. The possibilities are limitless when you partner with Kemal. Contact us now, and let&#;s turn your vision into reality.

Are you interested in learning more about precision mold parts? Contact us today to secure an expert consultation!