193 Appendix Appendix 1: Suggested Contents of a Mold Manual Description (possibly a photo) of the mold Date of building Serial number, size, weight List of patents applying to the mold List of third-party trade marks of components used Table of contents Safety of operation Specifications: What is required to operate the mold: Molding machine type, space, plant floor, hoist capacity, air supply, cooling water, lubricants, power, etc Safe handling of the mold Installation, startup, and operation Troubleshooting Mold storage Mold maintenance (frequency and procedures) Setup guide from the original testing of the mold Mold drawings and bill of materials Assembly drawing(s) Detail drawings of stack components Detailed drawings of all other mold parts, optional Drawings or specifications of special, commercial products used in the mold (valves, heaters, seals, etc.) 194 Appendix Appendix 2: Mold Set-up Guide Blank Mold Wizard Inc SET UP GUIDE Customer: _ Mold No: Job No.: _ Project Engineer: _ Tested by: Date: _ MOLDED PART Part Description: _ Part Wt (g): Shot Wt (g): _ Overall Cycle: Avg Wall Thick.: Flow Length: _ _ (sec) _ (shots/min) MATERIAL Type: _ Manufactured by: Number: _ Batch No: _ Color: _ Pre-Dry Temp & Time: % Concentrate: MOLD No of Cavities: Type: Single Face Stack Nozzle Bushing: Locating Ring (mm): Shut Height (mm): Mounting Bolts: Metric Inch Ejection System: Ejector Stroke (mm): Runner System: MOLD PROCESS TEMPERATURES AND PRESSURES Core: _ (°C) _ (°F) Pressure in (psi): Flow Rate: Cavity: _ _ _ (°C) _ (°F) Pressure out (psi): Gate Pad: _ _ (°C) _ (°F) Air Pressure (psi): (US gal/min or Litres/min) Cooling Tonnage Required: _ MACHINE Type: Extruder Dia (mm): Clamp Stroke (mm): Serial No.: Inj Pot Dia (mm): No of Accumulators: Auxiliary Equipment: HEAT PROFILE Machine NOZ DIS1 DIS2 S/P2 S/P1 B/HD _ °C _ °C _ °C _ °C _ °C _ °C _ °C _ °C _ °C _ °C _ °C _ °C S/Point _ °F _ °F _ °F _ °F _ °F _ °F _ °F _ °F _ °F _ °F _ °F _ °F Mold N/T1 N/T2 N/T3 N/T4 S/BAR X/MA H/R1 H/R2 H/R3 H/R4 Start _ °C _ °C _ °C _ °C _ °C _ °C _ °C _ °C _ °C _ °C _ °C _ °C Auto _ °F _ °F _ °F _ °F _ °F _ °F _ °F _ °F _ °F _ °F EXT6 EXT5 EXT4 _ °F NOTES (For different zone temperatures and/or special start-up procedures see notes below) EXT3 EXT2 _ °F EXT1 195 Appendix 2: Mold Set-up Guide Blank CLAMP CLAMP CLOSE Timer(s) Clamp Tonnage Set Points (mm) Close Velocity (%) (%) (t) (%) Mold Break (mm) (t) Clamp Pos (mm) CLAMP OPEN Timer(s) Open Mold Pos (mm) Set Points (mm) Mold Protection Velocity (%) Pressure (%) Set Point (mm) EJECTOR & AIR HYD EJECTOR AIR FUNCTION Set Set Point (mm) Hyd Ejec Start S/P (mm) Hyd Ejec Back (mm) Hyd Ejec Stroke (mm) Hyd Ejec Fwd Timer Hyd Ejec Counter 10 Set Timer (t) 196 Appendix INJECTION FILL Cycle Time(s) Pull Back Shot Size Inj Time(s) Set Points (mm) Trans Time(s) Injection Pressure Velocity (%) (%) (psi) Piston Pos (mm) TRANSITION Time (s) Position (mm) Cavity Press (psi) HOLD Inj Pres SCREW Hold Time (t) Back Press (%) (psi) Speed (%) CARRIAGE Hold Press (psi) (psi) Fwd Set P (rpm) Current (amp) EXTRUDER Stroke Back Pos (%) TIMERS & COUNTERS CLAMP Set INJECTION Mold Close Timer Exc Inject Timer Mold Open Timer Exc Cycle Timer Hyd Ejec Fwd Timer Hold Zone #3 Timer Hyd Ejec Stroke Ctr Hold Zone #2 Timer Hold Zone #1 Timer PRODUCT HANDLING Shooting Pot Pack Time Index Conveyor Counter Extended Decompression Parts Drop Off Delay Shut-off Noz Del Tmr Tilt Forward Time VALVE GATE Delay Valve Gate O/Tmr Ext Valve Gate O/Tmr Set Appendix 3: Example of Light-Weighting a Product and Increasing Productivity Appendix 3: Example of Light-Weighting a Product and Increasing Productivity A × stack mold for DVD cases (Fig A1) is a good example of the results of clever product design, weight reduction by thin-walling, and using advanced mold and handling technology Amongst other good design features, this mold is using valve gates per cavity located on the spine of the DVD case The productivity has increased enormously, and reduced the product cost considerably Box and cover are now one unit After ejection into a high-speed side-entry robot, the two case halves are flipped closed and are then held in a buffer storage to control shrinking and warping Figure A2 shows the side entry robot The tooling arms entering the mold take a total of 0.75 s to enter, grab the products, and retract The mass of the product has been reduced from the original 84 g, which amounted to 75% of the product cost, to 60 g At the same time, by selecting a stack mold, the number of cavities has been increased from to Cycle time is now s, for a production of 4,800 cases per hour, or more than 34 million per year As a result of redesigning (light-weighting) the product and getting better molds, the product cost has been reduced by 40% While the mold cost is considerably higher than before and the handling equipment was added, the capital cost per unit molded amounts to only a few percent of the total piece price These products run continuously for years, using the best quality molds with high cavitations, resulting in the lowest product cost 197 198 Appendix Figure A1 Side entry robot for the removal of DVD cases from the mold The cases are then folded and put in a buffer storage to prevent warping while cooling and shrinking outside the mold Figure A2 A × self-contained mold for DVD cases This mold shows another method of dragging and spacing the mold sections, using pull rods (A); (Courtesy: AWM Inc., Switzerland) Appendix 4: Buying a Mold Appendix 4: Buying a Mold If you were planning to buy a “dream house” for you family, you would first inquire to find some recommended architects and/or builders that specialize in private homes There would be no point to contact builders that specialize in industrial or commercial buildings You would probably approach one (or maybe or 3) and discuss with of them at length what you have in mind regarding size, shape, number of rooms, type of construction, and so forth They will then prepare a quote for you, including a sketchy outline of your planned house, the size and shape of rooms, the types of walls, height of ceilings, inside and outside finish, the type of floor finish, heating, air conditioning, and so on You also expect a complete set of detail drawings of the construction on completion The quotations must have a time line to completion of the job and the price and payment conditions After such quotations have been received from the builder(s), there is still time to negotiate terms and to change, add, or remove features, before the sales contract will be finalized It can be very expensive to make changes once the building has started This is really not different from getting a quotation for a mold But it is amazing how many people request quotations for molds, by just specifying the number of cavities and the type of machine in which the mold is to be run, without specifying what they expect of the mold, in the area of performance and mold life No wonder that quotations for such “unspecified” molds can run from very low to very high prices An example of this from real life was shown in the preface of this book The following pages show a typical quotation and a confirmation of order for a mold, as used by one of the major mold makers The quotation is only released after thorough discussion with the customer to understand what he really needs This procedure may appear overly detailed and costly, but it ensures that the customer is well served, and that there will be no misunderstandings when the mold is finished 199 200 Appendix Company XYZ Mold quote Budgetary Mold Quote Number XXXX REV X CUSTOMER: ABC Molding CONTACT: Mr Smith DATE: Product Description: Widget part number 123456 Machine: Description of the machine in which the mold will be run Jan 22, 2003 PRICES, $US Mold Description Mold Price Options Electrical Cables Water/Air Kit Machine × cavity $150,000 $36,000 Included Included 300T machine Exclusions: Embossing not included, if required will be quoted separately Re-cuts for part sizing and fit DELIVERY TO TEST Based on current workload, 12–14 weeks from receipt of purchase order, deposit, and approval of final part drawing Test date to be confirmed at time of order receipt Required mold test results: • Establish optimal processing conditions to achieve acceptable part quality • Optimize cycle time • Determine if re-cuts (lid fit, ensure proper filling) are required Estimated mold test duration: days (longer if re-cuts required) INCLUDED FEATURES • hour acceptance run with set-up report • Mold technical data manual • Mounting bolts, lifting bar, latches MOLD MATERIALS Item Material Hardness R.C Finish3 Cavity Gate Insert Gate Pad Core Base Core Insert Stripper Ring Shoe 420SS 420SS 420SS 420SS BeCu S7 SS 49–51 49–51 49–51 49–51 Pre-hard 52–54 28–36 Draw-Stone 0.08, Buff Draw-Stone 0.08, Buff Draw-Stone 0.08, Buff Draw-Stone 0.08 Draw-Stone 0.08 Ground Ground Surface treatments such as ENP or flash chrome plating are not included, and can be quoted separately if desired GATING Outside center hot tip 201 Appendix 4: Buying a Mold EJECTION Stripper ring, stripper plate actuated by internal pneumatic pistons ESTIMATED CYCLE TIME: seconds Estimated cycle is based on customer information and mold maker experience – this is not a cycle guarantee The mold maker will, on a best-efforts basis, optimize the molding process during the scheduled mold test to achieve optimal cycle time, shrinkage, and weight Notes on the product quality: • The thick sections in the stacking area may show a degree of sinking • Steel-safe re-cuts are not included and will be quoted as a separate item PRODUCT DESIGN This quotation is based on the customer supplying a completely detailed plastic product design and shrinkage values Part drawing assistance is available, not included in this mold price, quoted separately at a rate of $US XX/hour Lead time for the project starts only after approval of final product drawing Changes to the product design after the order is placed will extend lead time MOLD TESTING AND ACCEPTANCE The mold will be tested in mold makers test room Please send 1000 kg of PP test resin two weeks prior to test date INTERRUPTION CHARGE If the order is placed on hold, canceled, or if machine or mold design changes are requested after commencement of engineering and/or manufacturing, please understand that the mold maker may be faced with considerable expenses including production rescheduling, additional set-ups, handling, storage, inventory costs, obsolescence, etc Accordingly, an interruption charge may be required on all or part of the order RELOCATION In the event the mold maker’s equipment is relocated from its original installation, a review of applicable safety regulations and services (i.e., electrical voltage, frequency) and operating environment (i.e., temperature/humidity) must be completed Additional equipment modifications may be required to operate equipment safely and optimize equipment service Always contact the mold maker prior to relocating equipment and we will assist in assessing any required equipment modifications TERMS XX% With Order, YY% 30 Days prior to Test Date, ZZ% Net 30 days from Date of Shipment, Payable in U.S Funds EX WORKS Mold maker’s location, any local taxes (such as sales) applicable shall be paid by the customer The Customer is responsible for insurance from the Mold maker’s facility to the point of delivery VALIDITY This quotation is valid for a period of thirty (30) days and is subject to our confirmation of the order and credit approval WARRANTY For full details, please refer to the enclosed Standard Warranty Conditions Per: _ Estimator Mr Jones 202 Appendix Standard Warranty and Hold Harmless Agreement Injection Molds, Hot Runners, and Spare Parts The mold maker provides molds to produce articles, which meet customer specifications The mold maker assumes no responsibility whatsoever for the design or manufacture of any products made using this mold, but warrants the mold to be free from defects in material and workmanship, for a period of XXXX (XX) months from date of shipment The mold maker’s obligation under this warranty is limited to repair or replacement of mold parts This warranty does not cover the following: Repair or replacement of the mold due to normal wear or damage caused during routine maintenance Damage to mold components whose fragility is determined by product design Damage to the mold or to molded parts from not following recommended maintenance and operating procedures, as outlined in this Mold Manual Consequential loss, personal injury, damage to goods and/or equipment, work stoppages, delays, or slowdowns in production associated with any breach of this warranty on the mold Damage arising from mold modifications not included in the procedures in the Mold Manual Damage resulting from the use of any unauthorized parts, supplied, manufactured, or modified by procedures not included in the Mold Manual and the Parts List (Bill of Material) Transportation charges and local sales taxes for replaced or repaired mold parts Expenses resulting from meeting local codes and standards Any claims for loss, costs, or damages for personal injury or property damages arising out of the manufacture of molded products using this mold This warranty applies to the original purchaser only, and is non-transferable If you require mold parts under warranty, the mold maker may require damaged or defective parts to be returned to its closest office A purchase order will be required to cover the part(s) in question Upon return of the part(s), or on advice of the mold maker’s representative in the field, a credit note will be issued Mold Spare Parts Only Warranty The mold maker warrants the parts to be free from defects in workmanship and material under normal operating conditions The mold maker’s obliga- 214 Appendix Tensile Strength D-638 (1000 psi) (kg/cm ) Tensile Modulus (10 psi) D-638 Percentage Elongation at Yield D-638 Polyarylsulfone 13 914 3.7 13 Polycarbonate 8–9.5 562–668 3.3 100–130 Polycarbonate 20% GR 633 110 Polyethylene LD 0.6–2.3 42–162 0.14–0.38 90–800 Polyethylene MD 1.2–3.5 84–246 0.25–0.55 50–600 Polyethylene HD 3.1–5.5 218–387 0.6–1.8 30–1000 Polyethylene 30%GR 562 8.0 Polyethylene high MW 2.5–3.5 176–246 0.2–1.1 300–500 Ethylene vinyl acetate (EVA) 1.5–2.8 105–197 0.02–1 750–900 Polypropylene 4.3–5.5 302–387 1.6–2.3 200–700 PTMT 8.2 576 Polypropylene 30% GR 7.3 513 0.8 Polypropylene copolymer 2.5–4.5 176–316 1–1.7 200–700 Polyallomer 34 211–281 4-Methyl pentene-1 281 2.1 15 Polystyrene GP 5–12 352–844 4–6 1–2.5 Polystyrene GP 30% GR 9–15 633–1055 12 1.3 Polystyrene HI 1.5–7 105–492 1.5–5 2–80 Styrene-acrylo-nitrile (SAN) 9–12 633–844 4–6 SAN 20% GR 9–20 633–1406 4–14 Styrene-butadiene 0.6–3 42–21 0.01–0.5 300–1000 Rigid polyvinyl chloride (PVC) 5–9 352–633 3.5–6 100–1000 Chlorinated PVC 7.5–9 527–633 3.6–5 5–65 PVC/PP 5–8 352–562 100–140 Vinylidene chloride 3–5 211–352 0.6 10–250 Urethane elastomer 6.5–8 457–562 Phenol-formaldehyde (no filler) 492 250 400–500 600 7–10 1.5 215 Appendix 8: Mechanical Properties Flexural Strength D-790 (1000 psi) (kg/cm ) Flexural Modulus (10 psi) D-790 a Izod D-256 Rockwell Hardness (L, R, M Scales) (Shore-D Scale) 17 1195 M 110 12.5 879 3.4 12–18 M 70 13.5 949 3.4 16 M 91 0.08–0.6 NB D 45 4.8–7 9.5 337–492 668 0.6–1.2 0.5–15 D 55 1–2.6 0.5–20 D 65 R 70 1.3 NB 0.01–0.2 6–8 422–562 12 844 10 703 5–7 352–492 9–14 NB D 20 0.5–2 R 85–110 3.1 NB R 117 7.6 R 110 1–20 R 50–95 R 50–85 0.8 L 70 633–984 4.5 0.3 M 72 11–20 773–1406 8–10 M 80 5–12 352–844 3.8 0.5–11 R 50–100 14–19 984–1336 0.4 M 85 22–26 1547–1969 8–18 M 100 0.4–20 D 70 NB 0.4–1.5 NB 10–16 703–1125 15–17 1055–1195 3.4–6 1–6 R 120 11–15 773–1055 3.5–5 0.4–32 R 110 4–6 281–422 M 60 D 52 M 125 a 633 10 Izod impact – ft lb/in of notch (½ × ½ bar) 0.25 216 Appendix Appendix 9: Thermal Properties Properties chart for injectlon molding grade plastics ASTM D792 D648 Transp (TP) Amorphous Transluc (TL) Crystalline Opaque (O) Shrinkage Drying Req’d (%) (time@temp) (hours@°C) O,TP Amorphous 0.4 to 0.6 O,TP Amorphous 0.5 to 0.8 2–3@88–77 Acronym Full Chemical Name Solid Density (g/cm ) ASA Acrylonitrile-Styrene-Acrylate 1.07 ABS Acrylonitrile-Butadine-Styrene to 1.2 CA Cellulose Acetate 1.3 Transparent 0.3 to 0.7 2–3@60–70 CAB Cellulose Acetate Butyrate 1.2 Transparent 0.3 to 0.7 2–3@60–70 CAP Cellulose Propionate 1.2 Transparent 0.3 to 0.7 2–3@60–70 EVA Ethylene-Vinyl-Acetate 0.94 avg 0.8 TL,TP HDPE High Density Polyethylene 0.93 to 0.97 0.81 O,TP Crystalline 1.2 to 2.2 none HIPS High Impact Polystyrene to 1.1 0.9 O,TP Amorphous 0.4 to 0.7 none Ionomer Ionomer 0.94 to 0.96 Transparent Semi-Cryst LCP Liquid Crystal Polymer 1.5 to 1.7 TP,TL Liq Crystal 0.2 to 0.8 4–8@150 LDPE Low Density Polyethylene 0.91 to 0.93 TP,TL Crystalline 1.5 to none LLDPE Linear Low Density Polyethylene 0.90 to 0.92 TP,TL Crystalline 1.5 to none MDPE Medium Density Polyethylene 0.93 to 0.95 O,TP Crystalline 1.2 to 2.2 none PA66 Polyamide (Nylon 6/6) 1.1 to 1.4f 1.0 to1.2 Translucent Crystalline to 2.2 3–4@71–60 PA6 Polyamide (Nylon 6) 1.1 to 1.4 1.2 to 1.3 Translucent Crystalline 0.8 to 2.1 3–4@71–60 PAEK Polyaryletherketone 1.3 to 1.5f Opaque Semi-Cryst 0.1 to 0.6 2–4@175–150 PAI Polyamide-Imide 1.4 to 1.6 Opaque Amorphous 0.1 to 0.2 5@175 PAR Polyarylate 1.2 Opaque Amor./Cryst 0.6 to 0.9 3–4@175–150 PAS Polyaryl-Sulfone 1.36 avg Opaque Amorphous 0.6 3–4@175–150 PBT Polybutylene-Terephthalate 1.3 to 1.6f Translucent Semi-Cryst 1.5 –2 (0.5f) 3@150 NOTES: f = FILLED PROPERTY MPa · 145 = PS1 Deg F = (Deg C – 32) / 1.8 Melt Density (g/cm ) D1003 0.9 0.77 1.1 to 1.2 none (8@60) 217 Appendix 9: Thermal Properties ASTM Acronym Melt Temp (°C) Mold Temp (°C) Injection Speed Shear Rate or Temp Sensitive Resid Time Sensitive Max L/t No Flow Ratio Temp (1mm thick) (°C) Tonnage Required (tons/in ) Typical Inj Pres (MPa) ASA 230 to 260 40 to 90 ABS 195 to 240 38 to 93 slow, even NO YES 30–150 : to 120 to 140 CA 180 to 230 50 to 80 various YES 130–170 69 to 180 CAB 180 to 230 50 to 80 various YES 130–170 69 to 180 CAP 180 to 230 50 to 80 various YES 130–170 69 to 180 EVA 200 to 210 20 to 60 HDPE 200 to 280 10 to 70 fast NO NO 250 : HIPS 180 to 280 10 to 85 fast NO NO Ionomer 210 to 260 to 50 slow, mod YES LCP 400 to 430 240 to 280 medium LDPE 170 to 240 10 to 50 LLDPE 170 to 200 MDPE 135–150 100 to 2.5 100 to 200 200–250 : 130 to 100 to 200 NO 100 to 70 to 110 YES NO 200–300 : 370 to 80 to 120 fast NO NO 275 : 1.5 to 80 to 120 10 to 50 fast NO NO 250–300 : 90 1.5 to 80 to 120 190 to 260 10 to 70 fast NO NO 250 : to 2.5 100 to 150 PA66 270 to 320 20 to 100 fast YES YES 140–340 : 240–260 to 100 to 150 PA6 260 to 310 20 to 100 fast YES YES 140–340 : 190–200 to 90 to 150 PAEK 370 to 400 160 to 220 slow NO NO 170–200 : 370 3–4(6f) 160 to 200 PAI 305 to 370 205 to 220 fast YES MILD 140–340 : to 160 to 200 PAR 260 to 380 65 to150 moderate NO YES 30–100 : 3–5 (4–6f) 138 to 200 PAS 340 to 370 120 to 155 moderate NO NO 140–170 : PBT 240 to 270 50 to 100 mod., fast YES YES 160–200 : 220–250 NOTES: f = FILLED PROPERTY MPa · 145 = PS1 Deg F = (Deg C – 32) / 1.8 120–130 100–110 110 138 to 200 to 80 to 120 218 Appendix ASTM D792 D1003 D648 Acronym Full Chemical Name Solid Density (g/cm ) Melt Density (g/cm ) Transp (TP) Amorphous Transluc (TL) Crystalline Opaque (O) Shrinkage Drying Req’d (%) (time@temp) (hours@°C) PC Polycarbonate 1.2 to1.5f 1.1 Transparent Amorphous 0.4f to 0.7 PEI Polyether-Imide 1.3 to1.5f Opaque Amorphous 0.5–0.7 (0.2f) 4–6@150–130 PEK Polyetherketone 1.3 to1.5f Opaque Semi-Cryst 0.1 to 0.6 2–4@175–150 PEEK Polyether-ether-Ketone 1.3 to1.4f Opaque 30% Cryst 0.1 to 1.4 2–4@175–150 P ES Polyether-Sulfones 1.2 to1.6f Transparent Amorphous 0.3f to 0.6 3–4@150–135 PET Polyether-Terephthalate 1.4 to 1.7f O,TP Cryst./Amor 0.2 to 2–4@180–160 PETG PET (Co-polymer) 1.2 to 1.3 O,TP Amorphous 4@66 PMMA Poly-Methyl-Methacrylate(Acrylic)1.1 to 1.2 Opaque Amorphous 0.4 to 0.8 2–3@77–93 Polyester Thermoplastic Polyester 1.3 Opaque Amorphous 1.5 to 1.8 2–4@120–77 POM Polyoxymethylene (Acetal) 1.4 to1.6f 1.2 Opaque 80% Cryst 0.8f to none PP Polypropylene 0.9 to 0.92 0.77 TP,TL Semi-Cryst to 2.5 none PPO Polyphenylene-Oxide 1.1 to1.2f 0.96 to 1.0 Opaque Amorphous 0.2f to 0.7 2–4@115–107 PPS Polyphenylene Sulfide 1.3 to 1.9f 1.5 avg Opaque 65% Cryst 0.1 to 0.5 3–4@150 PS Polystyrene to 1.1 0.9 O,TP Amorphous 0.4 to 0.7 none PSU Polysulfone 1.2 to1.6f O,TP Amorphous 0.7 5@120 PVC Polyvinyl-Chloride 1.2 to 1.4 1.2 to 1.3 Transparent Amorphous 0.2 to 0.5 None (2@60) SAN Styrene-Acrylonitrile 1.1 to 1.3 0.9 O,TP Amorphous 0.3 to 0.7 2–3@80–70 TPUR Thermoplastic Polyurethane 1.2 to 1.3 O,TL Amorphous 0.8 to 2–3@110–104 O,TP Crystalline 1.2 to 2.2 none UHMWPE Ultra High Molecular Weight PE 0.93 to 0.94 NOTES: f = FILLED PROPERTY MPa · 145 = PS1 Deg F = (Deg C – 32) / 1.8 1.2 1.0 to 1.1 0.9 3–4@120 219 Appendix 9: Thermal Properties ASTM Acronym Melt Temp (°C) Mold Temp (°C) Injection Speed Shear Rate or Temp Sensitive Resid Time Sensitive Max L/t No Flow Ratio Temp (1mm thick) (°C) Tonnage Required (tons/in ) Typical Inj Pres (MPa) PC 270 to 325 80 to 110 fast NO YES 30–100 : 3–5 (4–6f) 138 to 200 PEI 340 to 425 65 to 175 med.-fast NO YES 230 PEK 370 to 400 160 to 220 slow NO NO 170–200 : 370 3–4 (6f) 160 to 200 PEEK 370 to 400 160 to 220 fast NO NO 200 : 2–4 (6f) 160 to 200 P ES 340 to 380 140 to 160 fast YES YES 60 to 120 : 300 to 10 160 to 200 PET 260 to 300 to 80 slow, even YES YES 80 to 200 : 240–250 to 70 to 160 PETG 190 to 275 20 to 30 slow-fast YES YES 80 to 200 : PMMA 200 to 260 38 to 60 various YES NO 130–150 : 160–170 2.5 to 100 to 200 Polyester 230 to 260 40 to 100 slow, even YES YES 80 to 200 : 70–80 to 80 to 100 POM 180 to 230 80 to 100 med.-fast YES YES 100–200 : 160–170 3.5 to 100 to 170 PP 230 to 275 15 to 65 fast NO NO 200–300 : 170–180 to3 100 to 130 PPO 250 to 315 82 to 110 fast YES YES 150–200 2.5 to 5f 120 to 180 PPS 300 to 360 40 to 150 slow YES NO 150 : 260–280 to 50 to 140 PS 180 to 280 10 to 85 fast NO NO 200–250 : 130–160 to 100 to 200 PSU 310 to 400 100 to 170 slow NO NO PVC 180 to 204 20 to 40 slow-mod YES YES SAN 220 to 270 to 60 YES YES TPUR 190 to 220 30 to 65 YES UHMWPE 200 to 280 10 to 70 NOTES: f = FILLED PROPERTY MPa · 145 = PS1 Deg F = (Deg C – 32) / 1.8 fast NO NO 100 : 150 : 195 370 100 to 160 80 to 100 120 70 to 140 130–170 35 to 140 120 to 70 to 140 120 to 130 to 200 220 Appendix Appendix 10: Typical Mold Materials Metric Units Prehardened Steels Property Temp (C) Chemical comp Tool steels P20 4140 NAK55 H13 H13 S7 0.33 C 0.40 C 0.15 C 0.38 C 0.38 C 0.3 Si 0.3 Si 0.3 Si 1.0 Si 1.0 Si 1.4 Mn 0.8 Mn 1.5 Mn 0.3 Mn 1.8 Cr 1.0 Cr 0.1 S 5.2 Cr 0.8 Ni 0.2 Mo 1.0 cu 3.0 Ni 0.2 Mo Stainless steels CPM9V CPM10V Ultimate strength (MPa) Yield strength (MPa) Elongation (%) Imp str (J) (V-notch) Elastic modulus (GPa) Therm exp (10E-6/C) Thermal cond (W/M C) Corrosion resistance Applications 20 28–32 28–32 40 (270–300 (270–300 (375 HB) HB) HB) 420 ESR 416T BECU3 BECU25 (prehrd) HT Aluminum Titanium 6061 T6 6A1-4V A2 D2 A10 O6 0.50 C 1.0 C 1.55 C 1.35 C 1.45 C 1.78 C 2.45 C 0.38 C 0.33 C 0.38 C 0.15 C 0.4 Be 1.9 Be 97.6 Al 6.0 Al 0.3 Si 0.2 Si 0.3 Si 1.2 Si 0.9 Si 0.9 Si 0.9 Si 0.3 Si 0.4 Si 0.9 Si 1.0 Si 1.8 Ni 0.6 Co, Fe, Ni 0.6 Si 4.0 V 0.3 Mn 0.7 Mn 0.6 Mn 0.3 Mn 1.8 Mn 1.0 Mn 0.5 Mn 0.5 Mn 1.1 Mn 1.4 Mn 0.5 Mn 1.2 Mn 0.28 Cu 0.3 Fe 5.2 Cr 3.2 Cr 5.3 Cr 12.0 Cr 1.9 Ni 0.3 Mo 5.3 Cr 5.3 Cr 16.0 Cr 16.7 Cr 13.6 Cr 13.0 Cr 1.0 Mg 1.3 Mo 1.3 Mo 1.4 Mo 1.1 Mo 0.8 Mo 1.5 Mo 1.3 Mo 1.3 Mo 0.1 S 0.3 V 0.2 S 0.2 Cr 1.0 V 1.0 V 0.2 V 0.8 V 9.0 V 9.7 V 42–44 49–51 54–56 54–56 56–58 58–60 58–60 53–55 60–62 49–51 26–36 18–26 (95–102 Rb) 38–41 (95 HB) 30–34 (2448 comp) (2454 comp) 1917 (2765 comp) 1917 (3599 comp) (3392 comp) 1896 1096 1765 945 924 1517 310 896 1000 1731 896 1310 689 717 310 572 807 1344 786 1172 620 648 241 483 5–25 3–10 1.0 Al Hardness (RC) DIN 420F 1.2316 (prehrd) (prehrd) Copper alloys 0.1 S 20 1007 965 1262 1386 1696 200 951 910 1041 1303 1744 400 793 751 882 1158 1469 20 800 758 1020 1117 1331 200 751 710 841 1048 1262 400 627 586 683 931 1062 20 17 18 1–15 15 13 20 73 51 30 27 200 81 60 12 37 30 (2034 comp) (2061 comp) 1475 (2123 comp) 1737 (2275 comp) (2744 comp) 28–36 36 (270–340 (340 HB) HB) 1076 924 1620 3–9 27 910 1469 820 1172 758 3–10 16 17 12 31 200 41 (Cnotch) 47 (unnotch) 58 (unnotch) 30 (unnotch) 73 (Cnotch) 35 (Cnotch) 50 193 207 221 221 221 200 200 214 193 193 11.0 11.0 10.5 11.5 11.5 400 98 76 11 41 34 20 207 207 207 200 200 200 193 193 200 200 200 200 186 186 193 186 186 275 12 827 11 19 30 207 179 138 131 110 117 70 114 400 186 186 179 172 172 179 172 172 200 12.6 12.8 12.6 11.5 11.5 12.1 11.7 11.0 11.7 11.2 11.2 11.2 11.0 62 48 17.6 17.5 400 13.5 13.5 12.2 12.2 12.4 11.3 10.8 11.3 12.6 11.7 11.7 12.1 24 9.0 20 29.1 42.7 24.7 25.9 25.9 29.1 26.1 20.1 25.9 21.4 21.4 16.9 23.0 23.0 24.9 249.1 103.9 167.0 6.9 200 29.6 42.2 25.8 25.9 26.1 29.7 27.1 21.1 27.0 19.0 23.9 23.9 28.7 400 31.1 37.7 26.8 26.5 26.5 31.0 28.7 23.0 28.5 24.7 Poor Poor Poor Poor Poor Poor Poor Poor Poor Poor Poor Poor Good Good Good Good Good Good Fair Good Plates, misc comp Plates, misc comp Mflds Nozs, H.R comp Cores, cavs, gates Gates, stripr rings Lock rings, stripr rings Wear parts Sliding surf Sliding surf High wear gates High wear parts Mold plates, slides Mold plates, misc comp Cores, cavs, gates Misc comp Noz tips Core caps, gate insers Cooling manif., T.O comp Insulators 9.4 8.6 24.9 (Note: Values shown are approximate depending on supplier and quality level of material.) 11.4 221 Appendix 10: Typical Mold Materials English Units Prehardened Steels Property Temp (F) Chemical comp Tool steels P20 4140 NAK55 H13 H13 S7 0.33 C 0.40 C 0.15 C 0.38 C 0.38 C 0.3 Si 0.3 Si 0.3 Si 1.0 Si 1.0 Si 1.4 Mn 0.8 Mn 1.5 Mn 0.3 Mn 1.8 Cr 1.0 Cr 0.1 S 5.2 Cr 0.8 Ni 0.2 Mo 1.0 cu 3.0 Ni 0.2 Mo Stainless steels CPM9V CPM10V Ultimate strength (KSI) Yield strength (KSI) Elongation (%) Imp str (Ft-lbs) (V-notch) Elastic modulus (PSIE06) Therm exp (10E-6/F) Thermal cond (BTU/ FTHRF) 70 Applications 416T BECU3 BECU25 (prehrd) HT Titanium 6061 T6 6A1-4V D2 A10 O6 0.50 C 1.0 C 1.55 C 1.35 C 1.45 C 1.78 C 2.45 C 0.38 C 0.33 C 0.38 C 0.15 C 0.4 Be 1.9 Be 97.6 Al 6.0 Al 0.3 Si 0.2 Si 0.3 Si 1.2 Si 0.9 Si 0.9 Si 0.9 Si 0.3 Si 0.4 Si 0.9 Si 1.0 Si 1.8 Ni 0.6 Co, Fe, Ni 0.6 Si 4.0 V 0.3 Mn 0.7 Mn 0.6 Mn 0.3 Mn 1.8 Mn 1.0 Mn 0.5 Mn 0.5 Mn 1.1 Mn 1.4 Mn 0.5 Mn 1.2 Mn 0.28 Cu 0.3 Fe 5.2 Cr 3.2 Cr 5.3 Cr 12.0 Cr 1.9 Ni 0.3 Mo 5.3 Cr 5.3 Cr 16.0 Cr 16.7 Cr 13.6 Cr 13.0 Cr 1.0 Mg 1.3 Mo 1.3 Mo 1.4 Mo 1.1 Mo 0.8 Mo 1.5 Mo 1.3 Mo 1.3 Mo 0.1 S 0.3 V 0.2 S 0.2 Cr 1.0 V 1.0 V 0.2 V 0.8 V 9.0 V 9.7 V 42–44 49–51 54–56 54–56 56–58 58–60 58–60 53–55 60–62 49–51 26–36 (355 comp) (356 comp) 278 (401 comp) 278 (522 comp) (492 comp) 275 159 256 137 145 251 214 (308 comp) 252 (330 comp) (398 comp) 132 213 119 170 0.1 S 70 146 140 183 201 246 400 138 132 151 189 253 750 115 109 128 168 213 70 116 110 148 162 193 400 109 103 122 152 183 750 91 85 99 135 154 70 17 18 1–15 15 13 (295 comp) (299 comp) 28–36 36 (270–340 (340 HB) HB) 156 134 235 3–9 70 54 38 22 20 400 60 44 27 22 750 72 56 30 25 70 30 30 30 29 29 29 400 29 29 29 27 27 28 20 110 3–10 16 13 23 29 35 (unnotch) 43 (unnotch) 22 (unnotch) 54 (Cnotch) 26 (Cnotch) 37 28 28 28 30 32 32 32 29 29 27 27 31 28 28 6.1 6.1 5.8 6.4 6.2 41 (Cnotch) 18–26 (95–102 Rb) 38–41 (95 HB) 134 220 45 130 190 30–34 130 100 104 45 117 195 83 114 170 90 94 35 70 5–25 3–10 40 12 120 11 14 22 750 27 27 26 25 25 26 25 25 400 7.0 7.1 7.0 6.4 6.4 6.7 6.5 6.1 6.5 6.2 6.2 6.2 6.1 750 7.5 7.5 6.8 6.8 6.9 6.3 6.0 6.3 7.0 6.5 6.5 6.7 70 16.8 24.7 14.3 15.0 15.0 16.8 15.1 11.6 15.0 12.4 12.4 400 17.1 24.4 14.9 15.0 15.1 17.2 15.7 12.2 15.6 750 Corrosion resistance 28–32 28–32 40 (270–300 (270–300 (375 HB) HB) HB) 420 ESR Aluminum A2 1.0 Al Hardness (RC) DIN 420F 1.2316 (prehrd) (prehrd) Copper alloys 30 26 9.8 13.3 13.3 14.4 11.0 13.8 13.8 16.6 14.3 20 19 16 17 9.8 9.7 10 13.3 16.5 5.0 5.2 144.0 60.1 97.0 4.0 5.0 18.0 21.8 15.5 15.3 15.3 17.9 16.6 13.3 16.5 Poor Poor Poor Poor Poor Poor Poor Poor Poor Poor Poor Poor Good Good Good 14.4 Good Good Good Fair Good Plates, misc comp Plates, misc comp Mflds Nozs, H.R comp Cores, cavs, gates Gates, stripr rings Lock rings, stripr rings Wear parts Sliding surf Sliding surf High wear gates High wear parts Mold plates, slides Mold plates, misc comp Cores, cavs, gates Misc comp Noz tips Core caps, gate insers Cooling manif., T.O comp Insulators (Note: Values shown are approximate depending on supplier and quality level of material.) 6.6 222 Appendix Appendix 11: What Characterizes a Good, High-production Mold? The difference between a well-designed and solidly built mold (A), planned to produce reliably good quality products at the lowest cost, and a low-cost mold (B) intended for the same product, can usually be seen right from the start, by visually comparing the two molds, and becomes obvious after operating the mold for a relatively short time Subject Mold (A) Mold (B) Concept and design Conceived from start with high productivity and lowest cost product in mind Much time is spent on the mold concept before starting the actual design, or beginning to cut steel Little if any thought has been given to the mold, except getting the shape of the product right, at the lowest possible mold cost Runner systems Much thought is given to decide on the most suitable runner system, the gating, cooling, and ejection of the products As long as the mold can produce the desired product, even only for a short length of time, it is considered acceptable Servicing of hot runners In hot runner molds, access to the hot runner system for minor servicing (changing heater bands or nozzle tips, etc.) is possible right in the machine, without removing the mold The mold must be removed from the machine for any service to the hot runners Strength of materials The strength of materials used in the mold is properly engineered This applies typically to the strength of cavities and cores to contain the high injection pressures and the size of mold plates to support both cavities and cores Cavities and cores are often not strong enough and expand or deflect when subjected to high injection pressures The mold plates are thin, just strong enough to hold the components in position Strength of supports Support plates are adequately heavy and sufficient supports are provided under the cavities and cores to ensure minimum deflection of the plates under load by clamping and during injection, thus guaranteeing quality products Support plates are too thin and supports under the cavities and cores are too small and often too far apart, resulting in excessive deflection of these plates, misalignment between cavities and cores and causing excessive wear in the alignment features Mold steel selection Mold steel selection is appropriate for the expected life and performance of the mold and often, the best quality steels and other materials are selected, without too much concern about the added cost (After all, with large production runs, the additional cost per molded piece is infinitesimally small) Any grade steel is used for the plates and cost of materials and mold components is a serious consideration 223 Appendix 11: What Characterizes a Good, High-production Mold? Subject Mold (A) Mold (B) Mold hardware Careful consideration is given to select the best quality of (purchased) mold components to ensure trouble-free operation Leader pins are often too short and too slender, just long enough to engage to LP bushings They deflect easily and not ensure proper alignment of the mold halves Tapers are usually too short, wear soon, and not hold the cores aligned with the cavities Mold alignment Alignment feature (leader pins, tapers) Long, especially unsupported leader pins are heavy to ensure minimum deflection They are long enough to protect the exposed cores from damage Tapers for alignment are sized proportional to the length of the core Leader pins are often too short and too slender, just long enough to engage to LP bushings They deflect easily and not guarantee proper alignment of the mold halves Tapers are usually too short, wear soon, and not hold the cores aligned with the cavities Tapers Alignment tapers are properly engineered, with specified amounts of preload, to ensure holding the matching parts in alignment securely Tapers are matched without proper preload, and therefore not provide alignment This can be easily seen just after a few days of operation when both matching surfaces are seen dirty or corroded Properly preloaded tapers are always shiny 10 Mold cooling Cooling channels are carefully planned for optimal size and location to provide maximum cooling efficiency and ensure highest productivity Cross drilling of the plates (which is possible because they are thick enough) simplifies the installation of the mold and improves the accessibility of the mold for servicing during startup Cooling channels are frequently placed almost as an afterthought, rather than planned from the beginning, and often omit difficult-to-cool hot spots They are then connected outside the plates and often require an excessive number of hoses to be connected; they are making setup and servicing more difficult and invite errors 11 Moving plates Moving plates, such as ejector plates, are properly guided and supported to minimize wear of delicate pins, etc Proper, often automatic, lubrication of wear points is provided Moving plates, such as ejector plates, are properly guided and supported to minimize wear of delicate pins, etc Lubrication of wear points is left to the operators of the machine 12 Mold mounting Mounting the mold to the machine is considered from the beginning and the most suitable mounting methods are provided Usually, only mounting ledges are provided for the use of rather unsafe mold clamps to hold the mold in position 13 Testing of mold The mold is thoroughly tested at the mold maker, not just for product sizes and fits but also for productivity of the mold, before delivery The mold is only tested to check the sizes of the products, and then shipped 224 Appendix Subject Mold (A) Mold (B) 14 Cost of extras Cost of extras are included in the mold price These extras consist of all necessary hardware to store, install, start up and run the mold To have these costs included makes it possible to compare fairly all potential vendors The following list shows some but not necessarily all of these items: (Note that when requesting a quotation, it is good practice to request that any such foreseen item or feature is included in the quotation) Mold making is a very competitive business, and by omitting to commit oneself on expected productivity and to consider necessary extras, the quoted mold price could become lower, thus more interesting to the unsuspecting buyer, who will later be faced with many additional expenses, or lack of productivity of the mold The difference could be as much as 20% of the mold price • Materials used for construction • Coatings and finishing including plating (molding surfaces) • Pipe fittings and hoses • Electrical cables • Mold feet, latches, and lift bars • Suggested spare parts • Crating and preparation for shipping • Cost of re-cuts • Cost of re-tests • Guarantees on product size • Expected productivity • Payment terms and conditions • Extent of warranty 15 Mold manual The customer is supplied with a “Mold Manual”, which documents all that is to be known about the mold and its accessories and vendor’s products It includes mold drawings, test reports, safety tips, and mold maintenance and trouble shooting instructions There is usually no such mold manual supplied 16 Productivity The molder smiles when he sees the mold producing large quantities of good quality products, without breakdowns The higher mold cost is soon forgotten With every of the frequent breakdowns the molder loses money, and any savings on the mold are soon surpassed by the costs of downtime and repairs Low productivity and higher costs per unit produced will cost the molder much more than was saved in the first place, particularly with large production runs Appendix 12: Advice for the Mold Designer Appendix 12: Advice for the Mold Designer Product Drawings Although it is the responsibility of the customer to provide a fully dimensioned and approved product drawing, before doing any mold design work always check these drawings to make sure they not contain errors or omissions A12.1 Product Drawing Critique Dimensions Are they plastic (final product) or steel (mold) dimensions? (Normally, a plastic product drawing shows the dimensions after shrinkage.) Artwork/surface finish The artwork and surface finishes must be supplied by the customer Wall thickness Can product fill easily and completely as it is drawn by the customer? Are the radii sufficient to help filling or are there any pinch points? Plastic must always flow from thick to thin Drafts Question any negative or no draft and determine if the product can be ejected Air ejection requires a minimum of 1° draft, but better 1.75° or more Product drawings must show all drafts and mismatches All Geometry defined? Make sure that all radii, angles, etc are defined by the customer Note areas where a minimum radius of 0,08 mm is required Parting line/split line The locations of the parting line and all split lines must be shown on the product drawing and approved by the customer Printing areas and/or cosmetic requirements for the product may require that these locations be reconsidered and moved The customer must approve all final parting line and split line locations Sink marks Notify the customer of areas were sinks may occur (thick sections or ribs) and get his approval 225 226 Appendix Gate location and gate vestige Determine if the gate vestige will be an issue If the bottom of the container is flat or the customer will print over the gate, the gate position could become a problem A recessed gate should be considered in these cases It is recommended to always use a dimple! A dimple is used to prevent gate cracking in PP and PS parts It also aids filling of the products Stacking Will the products stack and de-nest readily? 10 Shrinkage/warpage Shrinkage data must be provided by the customer Avoid any flat bottoms A domed bottom will prevent warpage If you cannot dome the bottom, suggest ribs or a foot to aid in stability ALWAYS question possible warpage in rectangular products Intensive cooling in strategic areas and thicker walls can reduce the problem 11 Features to be left off mold until after first mold test? Normally, pull rings, which aid in part transfer are left off for the first test In some cases, undercuts (on lids, etc.), and occasionally engravings are left off until after the mold test 12 Leave stock for lid fit? Normally, stock is left on the lid undercut for the first test to determine shrinkage and lid fit requirements 13 Ribs Any ribs must be shown in plan, top and side view The rib must have draft in every direction The rib should be no thinner than 0.5 mm and be no greater than 75% of the nominal wall section to avoid sinks A12.2 Stacking of Products A critical design festure is the ability to stack the product Some products are not meant to stack except for saving space in shipping There are several common methods to stack containers and lids, where stacking is an important feature Containers are often stacked using a step (a so-called stacking shoulder) near the lip or the base Alternatively, stacking lugs or ribs can be used at the lip area or in the bottom of the cup Flat products most commonly use a stacking bead for alignment A12.2.1 Stacking Clearances Stacking clearances are required to separate the products after stacking This air gap should allow them to separate with gravity However, if the clearance is too large, the containers or lids can shift and slip off the stacking ledge Appendix 12: Advice for the Mold Designer Clearance is dependent on height, diameter, wall thickness, draft, tackiness of the material, surface finish, and method of stacking (rib, shoulder, bead) A12.2.2 Stacking Engagement Stacking engagement ensures that stacked containers or lids will not collapse and telescope together In the case of lids, it prevents the parts from sliding off of one another when stacked Note that on the plastic part drawings, stacking engagement is dimensioned in two ways One method is the distance from the intersecting edge of the part to the intersecting edge of the shoulder or rib Another is the actual horizontal contact between the parts The guidelines given here are based on the first method because the second method sometimes suggests there is no minimum engagement A12.3 Draft Angles Drafts are required both for stacking and for ease of ejection Question any negative draft and determine if the product can be ejected There are certain cases where negative drafts can be acceptable Mechanical means (stripping) are normally used to remove products with zero draft, although in some exceptional cases removel is accomplished with air ejection The use of air ejection is preferred for several reasons: the mold is easier to manufacture, maintain, install and requires far less maintenance The minimum draft angles should be 1° (1.75 degrees or more are better.) Mechanical ejection should be considered when draft angles are less than 1° Many factors must be considered when deciding whether to use air or mechanical ejection, or a combination of both Surface finish (polished can be very difficult to air eject), type of resin, temperature at ejection, presence of static electricity, and product geometry all affect air ejection A12.4 Wall Thickness There is tremendous pressure on the plastics industry to reduce the amount of plastic in the product The reasons are twofold First, a lighter product is a more cost effective product And second, the public wants to reduce the amount of plastic being sent to landfill sites Due to this pressure there is a trend to reduction in product weight There are, however, limitations on how thin we can go The limitation on wall thickness is a function of the distance the plastic has to travel from the gate to the parting line, the resin used, and the number of cavities in the mold 227 228 Appendix Appendix 13: Surface Finishes The following table can be used to determine some typical molding surface finishes Micron Micro inch SPI # Symbol Manufacturing method Applications 0–3 A-1 0.025 ∇ Lapping, 8000 diamond Petri dishes 0.05 ∇ and buff 900 stone, 8000 diamond polish Test tubes 0.08 ∇ and buff 900 stone, 3000 diamond polish Styrene tumblers 10 A-2 0.1 ∇ and buff 600 drawstone, 3000 diamond polish Opaque Shiny surface 10–20 4–8 C-3 0.1–0.2 ∇ 900 drawstone Opaque surface (stack shoulders) D-2 0.1–0.2 ∇ and v hone 900 drawstone, vapour hone Matte surface (cores, gate pad) 15–20 4–6 0.15–0.2 ∇ v.hone, lt buff 900 drawstone, vapour hone, light buff Semi-opaque (‘clear’ cores) 10–15 4–6 0.1–0.15 ∇ v.hone and buff 900 drawstone, vapour hone, buff Semi-opaque surface (cavities) 20 0.2 ∇ and buff 600 drawstone, 3000 diamond buff Preform inserts 20–30 8–12 0.2–0.3 ∇ 400–600 stone Technical parts D-3 0.2–0.3 ∇ and sand blast 400–600 stone, sandblast Texture finish 0.4 ∇ 220–300 stone 40 16 Notes: A tool steel finish kit is available through the D-M-E Company as an official SPE/SPI kit The newest SPE/SPI codes were achieved using the specified media (diamond paste) as a guide and hand operations Frosting (e.g., on tumbler sidewalls) should never be specified with any depth since it is a surface finish only (i.e., 21–24 Charmille) [...]... shown on the product drawing and approved by the customer Printing areas and/or cosmetic requirements for the product may require that these locations be reconsidered and moved The customer must approve all final parting line and split line locations 7 Sink marks Notify the customer of areas were sinks may occur (thick sections or ribs) and get his approval 225 226 Appendix 8 Gate location and gate... from the gate to the parting line, the resin used, and the number of cavities in the mold 227 228 Appendix Appendix 13: Surface Finishes The following table can be used to determine some typical molding surface finishes Micron Micro inch SPI # Symbol Manufacturing method Applications 0–3 1 A-1 0.025 ∇ Lapping, 8000 diamond Petri dishes 5 2 0.05 ∇ and buff 900 stone, 8000 diamond polish Test tubes 8... will cost the molder much more than was saved in the first place, particularly with large production runs Appendix 12: Advice for the Mold Designer Appendix 12: Advice for the Mold Designer Product Drawings Although it is the responsibility of the customer to provide a fully dimensioned and approved product drawing, before doing any mold design work always check these drawings to make sure they do... and would appreciate receiving your formal Purchase Order and deposit cheque at your earliest convenience John, we thank you for your valued order and we look forward to working with you on this program Should you have any questions or comments, please do not hesitate to contact either me or David Jones Best regards, Jack Brown Project Engineer cc: David Jones Accounts Payable 208 Appendix Appendix... plates, slides Mold plates, misc comp Cores, cavs, gates Misc comp Noz tips Core caps, gate insers Cooling manif., T.O comp Insulators (Note: Values shown are approximate depending on supplier and quality level of material.) 6.6 222 Appendix Appendix 11: What Characterizes a Good, High-production Mold? The difference between a well-designed and solidly built mold (A), planned to produce reliably good... 240 93 96 110 97 102 116 2 2.9 160 218 160 140 250 165 232 71 102 71 60 121 74 111 3.6 4 3.3 4–20 3.7 2.7 13.5 7 7.2 127 3 4.5 19 5 Thermal conductivity [(cal) (cm)/(s) (cm2) (°C)] · 10–4 260 212 Appendix Appendix 8: Mechanical Properties Mechanical properties of plastic material (these are typical values) 2 Tensile Strength D-638 (1000 psi) (kg/cm ) Tensile Modulus 5 (10 psi) D-638 Percentage Elongation... 0.4–20 D 70 NB 0.4–1.5 NB 10–16 703–1125 15–17 1055–1195 3.4–6 1–6 R 120 11–15 773–1055 3.5–5 0.4–32 R 110 4–6 281–422 1 M 60 D 52 M 125 9 a 633 10 Izod impact – ft lb/in of notch (½ × ½ bar) 0.25 216 Appendix Appendix 9: Thermal Properties Properties chart for injectlon molding grade plastics ASTM D792 D648 Transp (TP) Amorphous Transluc (TL) Crystalline Opaque (O) Shrinkage Drying Req’d (%) (time@temp)... = FILLED PROPERTY MPa · 145 = PS1 Deg F = (Deg C – 32) / 1.8 fast NO NO 100 : 1 150 : 1 195 370 100 to 160 80 to 100 120 70 to 140 130–170 35 to 140 120 5 to 2 70 to 140 120 3 to 4 130 to 200 220 Appendix Appendix 10: Typical Mold Materials Metric Units Prehardened Steels Property Temp (C) Chemical comp Tool steels P20 4140 NAK55 H13 H13 S7 0.33 C 0.40 C 0.15 C 0.38 C 0.38 C 0.3 Si 0.3 Si 0.3 Si 1.0... slides Mold plates, misc comp Cores, cavs, gates Misc comp Noz tips Core caps, gate insers Cooling manif., T.O comp Insulators 9.4 8.6 24.9 (Note: Values shown are approximate depending on supplier and quality level of material.) 11.4 221 Appendix 10: Typical Mold Materials English Units Prehardened Steels Property Temp (F) Chemical comp Tool steels P20 4140 NAK55 H13 H13 S7 0.33 C 0.40 C 0.15 C 0.38... to any count therein This shall include adding the mold maker or any affiliate or subsidiary thereof to any existing litigation and shall also include any and all counts in said litigation 203 204 Appendix Appendix 5: Suggested Format of a Confirmation of Order Confirmation of Order February 9, 2002 ABC Plastics 123 North Street Jones, NY 90120 Attention: Mr John Smith, Purchasing Manager Reference: