There is a wide variety of mouldings available on the market, ranging in complexity from simple to complex. Advances in Injection Molding technology, tooling, and manufacturing techniques have made it possible to manufacture increasingly complex molds.
A continuous, ever-increasing range of high-quality components has been developed by the standard components industries in tandem with these advances to significantly simplify designs and tool constructions, and to reduce both design and machine tooling time.
Different solutions are available to solve problems with undercut or ejection.It is apparent that more and more designers and toolmakers are implementing these novel components into their designs, as they offer self-sufficient solutions to retaining and releasing an undercut in the mould tool. Such components offer advantages to both the designer and the toolmaker.
Though the shapes of moulds produced can range from simple to complex, it is possible to categorize mould designs based on how they are derived from existing and proven moulds; or whether they require a totally new design, as in the case of some new components.
In situations where this is possible, converting and modifying an existing design into a mould for the part is clearly the best option since all the bugs have already been ironed out and the part’s functional behaviour has already been fully tested under production conditions.
The demand for new designs, and, if necessary, extending existing solutions, cannot be completely avoided. Sometimes, completely new solutions are needed.
A designer must be able to assess the likelihood of success based on previous experience when making design decisions in the latter case.
In order to construct the simplest possible solution to the problem, the designer should always attempt to ensure the design is as simple as possible.
In the event that a sample moulding has been provided during the design phase, it makes it much easier to identify the gate position and size, the location of the ejector pins, etc.
It is generally recommended that a new tool be designed based on the performance of a previous tool if the goal was to produce the same result.
Generally speaking, simple designs are more reliable so they’re easier to manufacture. It’s a good practice to use tried-and-tested designs and moulds instead of totally new ones.