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Types of Molding Dies

Types of Molding Dies

Depending on the application and budget, dies are made from a variety of materials. For example, a production die may be made of aluminum/epoxy alloys. Generally, the cost of tooling will decrease with long-term use. Some manufacturers are now using 3D printing techniques to produce molds. However, these techniques can be costly. A good rule of thumb is to select the type of mold according to the application. Generally, aluminum die casting tooling provides the good economy for large-volume production. However, plastic injection molding requires more complex tools that may cost more.
When making a mold for plastic injection molding, silicone rubbers can be used. Molds can also be made of aluminum, copper, and epoxy. These materials are the many common. However, there are dozens of other materials that can be used. Selecting a material based on the application and budget can reduce costs.
Metal cores are the many common type of core used in injection molding. Usually, they are 0.125 to 0.25 in thick and are molded in two halves. These cores are typically used for moldings with simple internal surface details. Unlike polymer cores, metal cores can be molded in traditional injection molding machines. However, they require a significant development time. In addition, their melting temperature is twice the temperature of the plastic shot into the mold. This can cause distortion of the plastic shot.
Other metals used in mold making include brass, copper, and aluminum. These materials are used to produce a variety of parts. A common alloy is 58% bismuth and 42% tin. This alloy has a melting point between 98 and 800 degF. It is also used to make molds for nylon 66. The melting point of this alloy can be altered by altering the alloy ratio.
Tool steel is another common mold material. This type of steel is designed for high strength and impact resistance. It is also easily machined. The cost of tool steel is high, however. The alloy is also known for its high resistance to wear. Other types of mold materials include brass, copper, and epoxy.
Polymer cores are generally used for moldings that require little internal detail. Polymer cores are usually 3.2 to 6.3 mm thick. They are often molded in two halves and ultrasonically welded together. Polymer cores are less common than metal cores, but they are typically used in small production runs. They are also the many affordable type of core used in injection molding. However, they are less precise than metal cores.
The material used in making molds for die casting and injection molding is important. Both processes use a wide variety of materials, and each has its own advantages. However, the key differences between the two methods are the materials used to make the parts and the processes' cost.
Injection molding is a faster process that involves less labor and material scraps. However, it may not be suitable for applications where the parts will be exposed to harsh environments. Injection molding may also be limited to small parts.





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