Mold Manufacturing

Mold Manufacturing

Mold Manufacturing

During our sales engineering process, we evaluate each project scope in order to define the right manufacturing process flow. Size, geometry, volume, product cost and material chemistry all play a roll in casting process selection. Once we define the most suitable casting process, we can then begin our mold manufacturing process. From a small single cavity compression tool designed to produce a single 100g part, to a large low pressure injection tool designed to mold large 350lb parts, to open cast molds designed to produce 2 parts per cast or a 25 cavity transfer compression tool, Precision Urethane has the experience and technology to design and machine precision high quality tooling.

Mold / Tooling Design

Mold / Tool design is one of the most critical aspects of producing a quality-molded polyurethane product. As part of our production process, we determine what type of processing method is best suited for the product. We work closely with our customers to determine the material, production volume, part cost and tolerances when designing our tooling. Once we have established the processing method best suited for our customer's product, our engineering team then designs the mold in SolidWorks. By designing the mold in house, we can do a complete process walkthrough of the material flow, gating design and de-mold process. Designing our tooling in-house allows us to maintain shorter lead times and control every aspect of dimension, finish, and tolerance without costly delays from subcontracted tool modifications.

The image to the right is an example of a transfer injection tool used to cast a 90lb 70 Shore D polyurethane part.

Programming / Tool pathing 

To effectively operate a CNC machine, tool paths must be created to define the cutting path for the tooling. The goal of programming a CNC machine is to enable a machine tool to achieve automatic, precise and consistent cutting motion. To do this properly, the CNC requires a set of programming instructions call G codes which are a set of X,Y & Z  coordinates which tells the machine how to machine the part. We use the Mastercam CAM system for programming our molds and finished parts. This process is performed by using the 3D model created in SolidWorks, then selecting the surfaces of the model and defining the tooling and the path each tool will take in the machining process. The CAM system will output a video of the toolpath to machine the bottom of the mold noted above.

Finished Product

Once the tool manufacturing process is complete, the end result is a quality well engineered cast urethane product. 

Several hundred 90lb parts were manufactured for an amusement park underwater support system currently still in use in Florida.