What Is 3D Printing?

3D printing is also known as additive manufacturing. A 3D object is constructed using a CAD (computer-aided design) model or digital 3D model. 3D printing has numerous applications in product design, aviation, the medical industry and more. In medical settings for instance, 3D printing is used to make valves and stents used in surgical procedures and even prosthetics.

This method is most suited for small or medium-sized projects that have a one to two week turnaround time. It’s most commonly employed when the project involves intricate designs that can’t be produced in a custom mold, or for designs that are subject to last-minute changes.

3D printing is also very useful in prototyping applications. It is used in the creation of prototypes before final production, as it is much more time and cost effective than other methods available in the market.

It is also very affordable compared to traditional injection molding or manufacturing. For this reason people pursuing hobbies involving the creation of 3D objects also commonly use this method.

Benefits of 3D Printing

3D printing has a number of different benefits including:

3D Printing Has a Low Entry Cost

To start 3D printing at home, all you need is a desktop 3D printer and a supply of materials so the initial investment is low. If you are not expecting to use the printer regularly, it’s even cheaper just to outsource your printing to a specialist like us as there are no upfront costs, and you only pay for each 3D printed part that is produced. The more parts that are printed the cheaper they are, until you get to the point where the economies of scale make injection molding significantly cheaper.

With 3D Printing It’s Easy to Change Designs

Since 3D printing is an additive process the design can be changed easily, even in the worst case scenario during production (although this is uncommon). Usually you would change the CAD file in between prints to iterate on your design if you’ve noticed any design flaws in the original print.

3D Printing Allows Us to Create Intricate Designs

Since the product is manufactured layer by layer in 3D printing, you can create very intricate designs and parts that are not possible to make with regular manufacturing techniques, like creating internal spaces that are not accessible from the outside for instance.

Disadvantages of 3D Printing

There are also some disadvantages to 3D printing however, including:

3D Printing Can Be Time Consuming

Most printers can only produce one or two units at a time, so it takes a lot of time especially if you want to mass produce something. For this reason it’s better to outsource your printing to a 3D printing company like us that has access to multiple machines. If you want to produce something en masse on a very large scale however, it’s cheaper and quicker to use traditional manufacturing methods like injection molding.

3D Printers Have a Size Limit

3D printers are pretty innovative folk. There are for example 3D printers which can be used to print houses out of concrete in a matter of hours. In most cases though, the size of the products that can be created is limited by the size of the printing area and capacity of the printer. Hobbyist printers tend to be quite small, professional printers can be much larger. In some cases for large products, the print must be split into component parts which are later reconstructed.

3D Printing in Lower Resolution Has a Rough Finish

Since 3D prints are built layer by layer the end product will have a rough finish (although you can choose how fine you want the finish to be by choosing a higher resolution print. A finer finish is more expensive). Because the finish is not perfect, time and energy needs to be spent to machine the product after completion if you want a smooth finish.

3D Printing is Not Able to Be Done in Dense Materials (Yet)

3D printing technology is coming ahead in leaps and bounds but at this point in time printing in very dense materials is not very practical.

What Is Injection Molding?

Injection molding is a manufacturing process that produces parts by injecting material that has been heated to the point of melting into a mold. Parts can be made using materials ranging from metals and glass to different types of plastic polymers.

It is most suited for high volume production and designs that require a strong and smooth finish. It is most commonly used after the final design has been approved after going through a prototyping stage, as the molds used in injection molding are pricey, and it’s best not to make a mold until any issues in your prototype have been ironed out.

Benefits of Injection Molding

Injection Molding is Suitable for Mass Production

When using injection molding to mass produce a product, a large number of molds can be used at the same time, which drastically cuts down production time. Injection molding is much quicker than 3D printing, which is why it’s used to manufacture products at scale.

Inject Molded Products Have a Strong Finish

A single layer of poured material is used to create products made via injection molding. This means that there will be no fissures or weak spots. Injection molding can also be used to create products using dense materials like concrete.

The Injection Molding Process Has Minimal Wastage

Since each mold uses the exact amount required for one design there is very little to no wastage of materials or resources and little required machining once the part is created.

Disadvantages of Injection Molding

Intricate Designs Don’t Work Well

If your design is very intricate or involves a lot of angles or internal spaces, the product can break when being taken out of the mold, or be impossible to create through this process.

Changing Design Is Costly

Injection molding can only be done with an expensive metal mold that will hold up to repeated use. It is difficult, therefore, to make last-minute changes or rework the mold. In most cases if you are not happy with a product you will need to make a new mold from an updated CAD file, which is expensive.

Injection Molding Has a High Initial Investment and Cannot Be Done By Hobbyists

The equipment used in the injection molding process is expensive. It is mostly used in commercial manufacturing facilities. Moreover, making molds is a costly affair. That’s why it’s best to use a manufacturing company like us. We already have all the required machines, that means you only need to pay for the mold/s you need. We can even store them for you in between production runs if you’d like.

3D Printing vs. Injection Molding Pricing Compared – Which is More Cost Effective?

The pricing and profitability of each method above vary based on a number of factors. The main determinants of cost are the size of your run and the complexity of your design. You can find out specifically how much does 3D printing services cost here.

Size of Your Run

The initial design and molding costs will be higher in the case of injection molding. Comparatively, 3D printing can be set up at a lower investment.

However, if the volume of your project is very high and you require more than 2,000 units, you can easily cover the initial investment costs by manufacturing en masse.

Injection molding is much faster and cheaper when the volume of output required is high. The per-piece cost becomes significantly cheaper than 3D printing if you want to produce very large volumes of parts or products, even with the initial cost of the mold factored in.

If you have a small or medium product run in mind, or are looking for bridge manufacturing services, then 3D printing or vacuum casting may be more cost effective. Even though the price per unit when taken by itself can seem higher than injection molding, since there is no large upfront investment in mold making the final cost will be lower in the case of a small run.

If you only need one or two items you’re definitely better to stick with 3D printing.

The Complexity of Your Design

If you want to update and change your design throughout the production process or if your design is very intricate and complicated then 3D printing is the way to go.

Injection molds cannot be altered easily and any sort of change means that you have to start over from scratch with a new mold. Each time you start over you will end up spending more money.

Moreover, intricate designs involving angles and spaces in the middle of the products cannot be effectively manufactured using injection molding. This type of product can easily break when being removed from the mold. Damaged products will lead to wasted materials and resources.

Therefore, 3D printing is more economical in the product development stage or prototyping stage when you will have to revise and rework your design multiple times, or in the case of complex items.

So Is 3D Printing Better Or Worse Than Injection Molding?

The truth is, both have their place in the manufacturing process, and both serve different needs. It’s not an either-or scenario. Depending on your requirements and budget you can choose either one or a combination of the two, eg. 3D printing for initial prototyping before mass production using injection molding. This is usually what we recommend for clients wanting to mass manufacture, as it is the cheapest approach overall.

If you are on the lookout for affordable, fast and high quality 3D printing or injection molding give us a call on or fill out our quote form. If you’re not sure which of these methods are best for your project we can suggest the one most suited for your needs based on your budget and requirements.

If you’ve enjoyed this article, you might also like this article on DIY injection molding.

Looking for applications of 3D printing? How about custom 3D printed chess sets!

Jason Vander Griendt

Jason Vander Griendt is a Mechanical Engineering Technician with years of experience working at major companies such as SNC Lavalin Inc, Hatch Ltd. Siemens and Gerdau Ameristeel. He is the CEO of JCAD – Inc., a company he started in 2006 after seeing a gap in the market for businesses who could assist clients through the entire product design and manufacturing process.

Jason has been featured in Forbes, has had his businesses analyzed and discussed in multiple start-up books, was a previous winner of the Notable8 Digital Innovator of the year award, and is a regular guest on business panels and podcasts. Email Jason at jason@jcadusa.com or follow him on LinkedIn.

The post 3D Printing Vs. Injection Molding – Is 3D Printing Cheaper Than Injection Molding? appeared first on J-CAD Inc. 1.888.202.2052.

If you have an idea for a silicone mold you would like to mass produce and sell widely, please contact us directly on info@jcadusa.com, by using the chat box below, or by filling out our quote request form, as the process described below is not efficient or cost-effective for production at scale. Happy reading!

Silicone kitchen molds come in handy when you want to make unique pastry items. It is unfortunate that almost every bakery you walk into and every mold you can buy features the same items and familiar basic shapes.

Customizing molds with your original design is the solution for a bland looking cake! 3D printing allows you to think outside the standard mold shapes and use the farthest reaches of your imagination for design.

3D printing a master to cast silicone kitchen molds is not just for those with advanced degrees in CAD or who can afford the nicest 3D printer. There are places that can help you with the design and printing processes if you don’t feel up to or can’t be bothered learning how to do it yourself.

But for budding DIYers out there, read on!

The Design Phase of Silicone Kitchen Moulds

The molding process starts with designing and printing a master to cast silicone molds for whatever it is you might be baking, whether it is a cake, bread, or batch of delicious cookies. While your limits for possibility are quite broad, it is important to know that 3D printing and silicone molds do have some boundaries.

You’re limited to a degree by size, and your design can’t have internal crevices or pockets, but in most cases if you can imagine it, you can make it.

Otherwise, take all the liberties you want when it comes to printing your mold masters. A never before seen shape or product could be right at your fingertips. Again, feel free to get in touch if you need help with CAD design or the initial 3d printing of the master. You might be surprised how cost effective it is!

Get Ready to Mold

It is important to note that molds are great at creating exact replicas of the 3D printed master model. Thus, any imperfection in the master that you have printed will be replicated as many times as you cast from it.

Choose the Appropriate Silicone

Choices abound when it comes to the types of silicone available. Rather than list them all here, we will provide a couple of quick tips about silicone measurements. If you can’t find food grade silicone at your local hobby shop, you can buy it online.

Silicone objects in general are measured on a scale called the Shore Hardness scale using a tool called the Shore durometer. A rigid item would be placed on the Shore D scale. A flexible object would reside on the Shore A scale. Silicones vary in hardness and the decision should be based on the desired final product.

Another choice lays ahead of the DIY mold maker – tin cure or platinum cure silicone? As their names imply, tin is the less expensive option. Why would you choose the higher-priced platinum cure? Well, if you are making silicone kitchen molds, you have to.

Platinum silicone is the way to go for a non-toxic, food-safe product (however please make sure that the silicone you are using has been certified as food safe by the FDA, this is really important!). Additionally, it is more flexible and easier to remove from the master. Finally, platinum cured silicone lasts longer than the tin cured variety, making it a wise investment long term and higher quality product despite the higher upfront cost.

A Quick Word on Mixing

The conversation detailing the process of mixing silicone would require a research paper-length discussion, but there’s plenty of info out there if you Google it. The most important tip is to be mindful of the “pot life” of a product. This is the amount of working time you have before the silicone begins to become solid.

Mixing and pouring should be completed prior to the pot life expiring. Do not plan on taking a break between these two steps.

Pour Your Heart Out

It is time to pour! Simply aim for the lowest part of your master and let the silicone fill from bottom to top. The master should be full, unless it is two sided. Two sided masters should be filled halfway. Tap it to allow any bubbles resulting from your pour to escape through the top. Remember, your pot life is very important to how long you have to complete this step.

Pour mixed silicone from a high enough height that the stream becomes slow and thin. This will allow you to pop the dreaded bubbles that ruin a perfect mold. The end result of a bubble is a little bump in your finished castings. A degasser is the only way to definitively remove all bubbles but following this tip should help, as degassers are not something your average hobbyist or kitchen enthusiast has access to.

The Cure and the Grand Finale

The sagest advice you could possibly get is to leave your curing silicone alone. One simple poke could result in a disrupted curing process and imperfect final shape. Add some time to whatever the suggested silicone curing duration states just to be on the safe side.

Remove the master model carefully to avoid accidentally ripping or breaking it. If any silicone made its way out of the master (flashing), you can cut it off with a sharp knife. Guess what? You did it. You successfully 3D printed a mold master model and silicone kitchen molds from it!

Blog post image by: medesign I.C. GmbH [CC BY-SA 3.0], via Wikimedia Commons

Related reading:

How to make concrete fountain molds

How much does it cost to make a silicone mold?

Jason Vander Griendt

Jason Vander Griendt is a Mechanical Engineering Technician with years of experience working at major companies such as SNC Lavalin Inc, Hatch Ltd. Siemens and Gerdau Ameristeel. He is the CEO of JCAD – Inc., a company he started in 2006 after seeing a gap in the market for businesses who could assist clients through the entire product design and manufacturing process.

Jason has been featured in Forbes, has had his businesses analyzed and discussed in multiple start-up books, was a previous winner of the Notable8 Digital Innovator of the year award, and is a regular guest on business panels and podcasts. Email Jason at jason@jcadusa.com or follow him on LinkedIn.

The post How to Make Silicone Kitchen Molds for Food, Cakes & Baking appeared first on J-CAD Inc. 1.888.202.2052.

Take the story of Vaso Karras for instance, who created a product to save dogs (and their owners!) from the pain of biting off more than they could chew. Vaso’s dog swallowed a 3 inch piece of bully stick, which got lodged in her stomach. After a trip to the vet and x-rays, Vaso decided to do something about it so that her dog and others like it would never have the same issue again.

Vaso contacted us a few months ago asking for help in finishing the design of her product idea for the “Bully Grip” and just a few short months later she was on TV showing the audience how it works! You can watch the interview here:

The idea came to her when her dog had to get an x-ray to figure out what was wrong after she started vomiting, not eating and showing other signs of stomach blockage after swallowing a large piece of bully stick. The X-ray revealed that her dog’s stomach was indeed blocked, and the vet had to operate to remove the piece of bully stick from the dog’s stomach.

That’s when Vaso decided to do something about this safety hazard for her dog and all other dogs so they could safely eat their favorite treat!

She calls it the “Bully Grip”. It works by gripping the end of the Bully stick, which helps stop dogs from swallowing larger pieces of the treats, as when the pieces become too small the dogs are not able to remove them from the grip themselves. As a result, by inserting the treat into her product idea design it’s impossible for any dog to swallow pieces that are too big.

You can learn more about how the product works and see it in action in this video:

As part of the project, we helped her finish the design and did all the required CAD mockups so it was ready for prototyping and manufacturing.

Next, we manufactured 1,000’s of units of her product at our manufacturing facility. She is now selling them online and shipping them all around the USA & Canada. What’s even more impressive is that she did this all on her own!

When we quoted her the price of manufacturing and molds she realized she didn’t need investors or outside help. She could do this herself and it was affordable. This meant that Vaso was able to keep 100% control of her company which is the ideal way to go if at all possible.

Congratulations Vaso we wish you much success with your product!

If you think Vaso’s idea is great and would like to purchase a Bully Grip, you can find her website at: https://bullygrip.com

If you have a product idea that you would like to turn into a reality, get in touch with us today, either through the live chat at the bottom of the page, or by contacting us here.

You might also like: Learn how to get your product on TV on Shark Tank

Jason Vander Griendt

Jason Vander Griendt is a Mechanical Engineering Technician with years of experience working at major companies such as SNC Lavalin Inc, Hatch Ltd. Siemens and Gerdau Ameristeel. He is the CEO of JCAD – Inc., a company he started in 2006 after seeing a gap in the market for businesses who could assist clients through the entire product design and manufacturing process.

Jason has been featured in Forbes, has had his businesses analyzed and discussed in multiple start-up books, was a previous winner of the Notable8 Digital Innovator of the year award, and is a regular guest on business panels and podcasts. Email Jason at jason@jcadusa.com or follow him on LinkedIn.

The post One of Our Clients Showing Off a Product We Manufactured on TV! appeared first on J-CAD Inc. 1.888.202.2052.

Basically, with the lost foam technique, all you have to do is to dissolve a part of the foam to maintain rigidity, leaving you with the remaining part of the foam when the piece is done. To clarify, what you do is; carve the foam into the desired shape, cover the carved foam with layers of epoxy and fiberglass, and then discard the foam.

This method is commonly used for nacelles and fuse glass but you can also create a hollow composite wing with this technique. Below are the steps involved in making a foam mold for fibreglass.

Before you get started though, you may like to have your mold mocked up as a CAD design. Making a CAD file is definitely help with! Get in touch using this link or by clicking the button below.

Mold making and fiberglass layup

Once you’ve finalised your design with a CAD file, the steps below will help you to prepare your layup for mold making.

Step 1:  Carve out a big chunk of the foam to match the design, and then cut out the sides using a carpet or kitchen knife. Rough cut the sides with the knife to complete the shape according to your dimensions and sand or otherwise smooth out the foam to achieve the perfect shape. This step shouldn’t take you too long, especially if the mold you’re creating is for a straightforward shape.

Step 2: Once you’re satisfied with the shaping and final outline of your foam piece, you can wrap up the foam model and plug any holes with a layer of packing tape. This will stop the epoxy / fibreglass you will be applying from seeping into the foam. You can also apply wax or a fine layer of vaseline to ease removal of the mold from the tape later on.

Step 3: Create a mechanism to rotate the foam core so that you can apply the resin / fibreglass on all sides effectively. You can do this by creating a fixture with a nail holding the foam in place at each end. Alternatively something like a potter’s wheel can come in handy.

Step 4: When working with fibreglass, make sure to take adequate safety precautions. Begin by applying a layer of fiberglass cloth, using 3M #77 spray before applying the epoxy. Apply the cloth in about 3” overlapping strips to ease the placement. You can mix your epoxy by using the manufacturer’s directions as a guide.

Step 5: Apply the amount of layers of fibreglass cloth you need to get the desired rigidity and allow the epoxy to harden for about 24 hours or more.

Finishing processes

Step 1: When the epoxy is all dried, you can sand off any problematic areas and rough up the entire surface.

Step 2: Mix a blend of microballoons and epoxy to use as a filling agent and brush the outside of the entire mold. Give the mold at least a day in order for it to harden.

Step 3: Once the casting has completely dried, sand off all the raised aspects of the casting until you get a smooth surface.

Removal of foam

Step 1: Remove the foam after you’re done with the sanding as it provides a strong base to apply pressure. You can use acetone or any other suitable chemical to remove the solvent, which will pour out freely once you open an area of the fuselage.

Step 2: Remove the packing tape by pulling a corner of the wax from the wing bay located inside. This will leave you with a clean interior as the wax will also remove the remaining foam paste that failed to pour out.

Does this process sound too confusing or complicated? There are alternatives, for example depending on the part you’re trying to create, 3D printing the part instead could be a very viable option. Get in touch using this link or buying clicking the button below to find out more about how we can help your project succeed.

Painting

Once the cast has been finished by sanding it, spray with Kylon primer or a similar product of your desired color. After painting or in between coats, be sure to continuously wet sand the surface until you achieve the desired smoothness.

Quick tip: In order to increase accuracy, you can make use of cardboard templates or a 3D printed to-scale miniature of your end part, and remember that fiberglass is a lot weaker on sharp corners. Therefore, consider adding more layers of fibreglass cloth to reinforce the corners and help you sand all the corners when you’re finishing the part without weakening it.

Making a foam mold from fiberglass is a relatively straightforward process, but it requires a high level of patience and consistency.

Applications of this process

For a cool example of how people are applying these and similar processes, check out our book:

If all this sounds too complicated for you, consider opting for a foam injection molding technique or 3D printing. It ensures top quality and you can easily outsource the whole process to experts without breaking the bank. If you’d like our help with your project get in touch for a quote here, or email jason@jcadusa.com

Jason Vander Griendt

Jason Vander Griendt is a Mechanical Engineering Technician with years of experience working at major companies such as SNC Lavalin Inc, Hatch Ltd. Siemens and Gerdau Ameristeel. He is the CEO of JCAD – Inc., a company he started in 2006 after seeing a gap in the market for businesses who could assist clients through the entire product design and manufacturing process.

Jason has been featured in Forbes, has had his businesses analyzed and discussed in multiple start-up books, was a previous winner of the Notable8 Digital Innovator of the year award, and is a regular guest on business panels and podcasts. Email Jason at jason@jcadusa.com or follow him on LinkedIn.

The post How to Make a Foam Mold for Fiberglass appeared first on J-CAD Inc. 1.888.202.2052.

The Author, Herbert Rees, has more than fifty years of experience working with molders, product designers, and other designers who are a part of the injection molding field. Which makes him a bit of an expert, doesn’t it?

Rees’ goal with Understanding Injection Mold Design is to explain the important details of good mold design while avoiding the use of overwhelming specialized details and phrases that readers would not be familiar with.

It is debatable whether or not he would have achieved that goal in our current timeline, sixteen years of research and trial and error later. However, when the book was first released it was quite popular.

The one and only review of this book that I could find, is a three-star rating review from 2013 from an Amazon user who suggests that the book isn’t necessarily worth its $25 – $35 cover price. Given how old this book is now, that is probably a fair assessment, as you might be better served looking for more up-to-date works.

The user explains that they found the book to be helpful, but not comprehensive by any means, he stated that they would need to buy more books to fully understand injection molding. The review goes on to say that the book’s major shortcoming has to be the illustrations, as they are black and white, and difficult to see because of the small size.

It is suggested that you look at other books before settling on this one unless you can find a cheap copy and specifically want to add it to your collection.

Beyond the one customer review, there is also an editorial review on Amazon which explains that Understanding Injection Molding Design doesn’t provide schematics of existing molds, but rather discusses the many factors to be considered when creating a mold.

The editorial review also states that the book includes coverage on topics such as:

• Starting as a newbie in the field of mold design
• The basics of an injection molding machine
• The basic mold design rules
• Selection of materials
• Common types of mold
• Estimating costs
• Machining; and
• Heat treatment

As far as the book’s summary itself… I found it to be a little bit bland to read. If I were looking through books on this topic, Rees’ book wouldn’t draw my attention like others would. And let’s face it, that’s an important part of writing a book… catching your reader’s gaze so that it doesn’t drift to another author’s work.

The summary includes the line “But regardless of size and type of the product to be Injection Molded, whether small or large, with single or multiple cavities, or who designs or builds the mold, the basic design principles are always the same”. A little wordy, isn’t it?

So in summary, this book may have been popular at the time of its release, but nowadays it wouldn’t be my first choice when delving into the world of injection molding for the first time.

If you have any question regarding Injection Molding, feel free to email jason@jcadusa.com or call us 1.888.202.2052.

Jason Vander Griendt

Jason Vander Griendt is a Mechanical Engineering Technician with years of experience working at major companies such as SNC Lavalin Inc, Hatch Ltd. Siemens and Gerdau Ameristeel. He is the CEO of JCAD – Inc., a company he started in 2006 after seeing a gap in the market for businesses who could assist clients through the entire product design and manufacturing process.

Jason has been featured in Forbes, has had his businesses analyzed and discussed in multiple start-up books, was a previous winner of the Notable8 Digital Innovator of the year award, and is a regular guest on business panels and podcasts. Email Jason at jason@jcadusa.com or follow him on LinkedIn.

The post A Review of Understanding Injection Mold Design by Herbert Rees appeared first on J-CAD Inc. 1.888.202.2052.

Not only does it reduce cost, it also enhances the quality as well as the efficiency of the final product. In the silicone injection molding process, pressure and temperature are the two most important variables. They both have a definite and sometimes irreversible (in the case of a negative outcome) effect on the silicone’s behavior.

You should have a complete grasp of the knowledge of how pressure and temperature (especially temperature) affect the final LSR product before attempting silicone injection (better yet, outsource to professionals instead!). This will aid in minimizing the risk of defects including but not limited to warpage, sink marks, and shrinkage. During the injection molding process, the silicone compound’s curing behavior is largely influenced by temperature, even more than it is by pressure.

Problems That Can Arise In Silicone Injection Molding Due to Temperature and Their Solutions

Due to neglect, ignorance, or just by mistake, a number of temperature-related problems can occur during the silicone injection molding process. These problems can lead to defects in the curing of the silicone or in the final products. These problems, their signs, causes, and possible solutions are highlighted below:

• Presence of lumps (or gelled particles) in finished product

If the tool temperature is too hot, you might notice that a part -or some parts- of the finished product appear gritty or lumpy. You might also notice that the cured sprue is visible inside the part. To solve this problem, reduce the tooling temperature at the gate.

• Blisters or bubbles

There might also be visible blisters or small bubbles all over the finished product. Moreover, it might have white or foamy edges. This can also be the result of the tool temperature being too high. To solve this problem, reduce the tool temperature and the defects should be prevented.

• Silicone isn’t cured

If after you have tried to cure the silicone, it still doesn’t portray all the signs of curing, there’s most likely a temperature problem. If the molded parts have a tacky feel or stick in the cavity, it means the tool temperature is probably too low. Increase the tool temperature, or check each individual cavity for temperature consistency. This should help to fix the problem.

• Incorrect part dimensions

If the finished parts come out too large or too small or they’re deformed, the problem might be caused by insufficient curing or by a change in shrinkage. Insufficient curing can be rectified by optimizing tool temperature, and shrinkage change can be corrected by checking throughout the tool for consistency in temperature.

To avoid all these problems, it’s advisable to delegate silicone injection molding to experts who will ensure that nothing goes wrong and that your finished products are perfect. Experts are always one step ahead of any possible problem and you have no reason to worry. If you’d like expert advice on your next silicone injection project, call 1.888.202.2052 or email jason@jcadusa.com.

You might also like:

Another article we’ve written about the process of do-it-yourself injection molding, or this one titled “How much does it cost to make a custom silicone mold?”

Jason Vander Griendt

Jason Vander Griendt is a Mechanical Engineering Technician with years of experience working at major companies such as SNC Lavalin Inc, Hatch Ltd. Siemens and Gerdau Ameristeel. He is the CEO of JCAD – Inc., a company he started in 2006 after seeing a gap in the market for businesses who could assist clients through the entire product design and manufacturing process.

Jason has been featured in Forbes, has had his businesses analyzed and discussed in multiple start-up books, was a previous winner of the Notable8 Digital Innovator of the year award, and is a regular guest on business panels and podcasts. Email Jason at jason@jcadusa.com or follow him on LinkedIn.

The post Silicone Injection Molding Temperature appeared first on J-CAD Inc. 1.888.202.2052.

During the process, it’s possible for defects to occur. These defects affect the quality of the product. Not to mention that the backlash from such product defects can cost manufacturers lots of money.

The defects in plastic injection molding are usually a result of problems with the material used, the process of molding, or the tools used in the molding process. Learning about each defect will help you get the best quality product possible with minimal risk of defects.

The most commonly occurring defects are:

• Burn Marks
• Voids
• Delamination
• Flash
• Flow lines
• Short shot
• Sink marks
• Warping

• Burn Marks

Causes: Burn marks are defects caused by the combustion of heated plastic. When there’s improper ventilation or prolonged heating, the plastic is burned. Another cause of burn marks in plastic injection molding is the burning of the resin itself or the burning of trapped air. When the injector speed is too fast, burn marks tend to appear as well.

The burn marks thus lead to discoloration that appears as black, brown or rust colored marks on the plastic.

How to avoid:

• Improve ventilation.
• Reduce injection speed and pressure.
• Ensure that operators run consistent cycles.

• Voids

These appear when air bubbles are trapped within or close to the surface of a molded product. In plastic injection molding, this particular defect isn’t viewed as detrimental to the overall strength of the product. However, when voids are bigger and occur more, the molded part is weakened.

Causes: When temperatures are so high in plastic injection molding, it causes the melt stream to trap gases and air. As a result, voids occur. Another cause is excessive moisture in the material. As the resin is heated, the moisture is converted to steam. This steam then forms a gas pocket.

How to avoid:

• Use less viscous plastic.
• Make sure that the mold parts have proper alignment.
• Increase holding pressure.
• Change ratio of wall thickness to the thin section.

• Delamination

This defect occurs when a separation exists between the layers of the molded plastic. This appears as a coating on the surface of a finished product. These ‘coatings’ can peel off of the underlying material.

Causes: The major cause of delamination in plastic injection molding is contamination. When the molten plastic is contaminated with foreign materials, the material can’t bond properly. Another cause is over-using of mold release agents.

How to avoid:

• Increase the speed of injection in little increments.
• Increase the temperature of the mold.
• Ensure that only compatible materials are mixed.
• Ensure the plastic is properly pre-dried before molding.

• Flash

Flash occurs when there’s an excess amount of plastic during the plastic injection molding process, and there’s a seepage. Once this seepage cools it needs to be removed from the finished product.

Causes: Flash is caused when the mold isn’t held in place with adequate force. Thus, the plastic seeps through the mold. It can also be a result of worn-out or aged molds. Another common cause is excessive injection pressure that pushes the molten plastic out.

How to avoid:

• Increase clamp force.
• Ensure proper maintenance of the mold.
• Adopt proper tooling design into repetitive processes.
• Reduce injection pressure.

• Flow Lines

These appear as wrinkles in the finished product. Flow lines occur as the result of variations in cooling speed of the material, where if a new layer is added before the previous one has cooled, wrinkles can appear in the finished product.

• Short Shot

A short shot appears when the heated plastic doesn’t completely fill the mold during plastic injection molding. The major cause is the inadequate quantity of prepared material for mold injection.

Causes: The major cause of short shot is the inadequate quantity of material. Also, using a very viscous material can lead to this problem since the material solidifies before filling the mold. Improper venting can also lead to a short shot.

How to avoid:

• Increase mold temperature.
• Ensure adequate degassing and venting techniques.
• Increase the flow rate.
• Use a less viscous material with a better flow.

• Sink Marks

They appear as depressions in the thicker areas of the finished product. Voids can happen when certain sections become solid first as a result of a low injection pressure. This shrinkage leads to marks in the area where the material is sunk into the void.

• Warping

Warping is evident in parts of plastic components that are meant to lie flat but somehow end up leaving gaps. This is a result of uneven shrinkage in different parts of the product because, for some reason during the cooling process, some components don’t dry evenly.

Now that you know about the defects that can occur in plastic injection molding, it’s a little easier to avoid them occurring. In many cases, it’s actually easy to prevent the issues mentioned above by choosing the right materials and the right techniques.

Companies that produce high-quality plastic products are well aware of the possibility of plastic injection molding defects and they’re always on the lookout for the new ways to avoid them.

If you need help with that, or any other injection molding queries, please give us a call at 1.888.202.2052 or email jason@jcadusa.com. We’re here to help!

Further reading: Is 3D printing cheaper than injection molding?

Jason Vander Griendt

Jason Vander Griendt is a Mechanical Engineering Technician with years of experience working at major companies such as SNC Lavalin Inc, Hatch Ltd. Siemens and Gerdau Ameristeel. He is the CEO of JCAD – Inc., a company he started in 2006 after seeing a gap in the market for businesses who could assist clients through the entire product design and manufacturing process.

Jason has been featured in Forbes, has had his businesses analyzed and discussed in multiple start-up books, was a previous winner of the Notable8 Digital Innovator of the year award, and is a regular guest on business panels and podcasts. Email Jason at jason@jcadusa.com or follow him on LinkedIn.

The post Plastic Injection Molding – Defects That Can Occur and Troubleshooting Guide appeared first on J-CAD Inc. 1.888.202.2052.

Here’s Why You Shouldn’t Get a Silicone Injection Molding Machine

If you own a business that uses or produces a lot of silicone-based items, you might be tempted to get your own silicon injection molding machine. While you think you might save you a lot of money in the long run, you’re also overlooking the amount of money it takes to maintain injection molding machines and the manpower it takes to oversee the silicone injection molding process.

This whole process isn’t for novices and you need an expert to look after the machine and see to its day to day running. The amount of money it will take to engage the services of this expert or the amount of money it will take for you to get trained can quickly accrue.

So what’s the solution? Outsource the process instead (and do it surprisingly cheaply).

There are a few reasons it’s better to outsource silicone molding instead of purchasing a silicone injection molding machine yourself. Here are four of the most valid ones:

• Expertise is required

Liquid silicone molding requires a very high level of expertise. For this reason, it’s better left to skilled, highly-trained professionals. If you operate the silicone injection molding machine without the required expertise, you’re going to end up causing yourself lots of problems, wasting time and money in the process.

• Knowledge of different silicones

Apart from the expertise needed to handle the equipment, you also need to have a broad knowledge/understanding of the different types of silicones available and the right one for each type of product you want to fabricate. If you use a low-quality material or the wrong silicone for the type of product you want to produce, defects are unavoidable.

• It’s time-consuming and money-draining

Silicone injection molding takes a lot of time and energy. Purchasing the machine and raw silicone (you need different types for different products, so you have to purchase a variety of materials in advance) costs a lot of money. Save your money, time, and energy by outsourcing to cost-effective companies (like us here at JCAD-Inc.!).

• The machines are big and need ventilation!

No matter how compact and contemporary a silicone injection molding machine is, it requires space. It’s great if you have that space, but also consider the space that’s going to be required around the machine (not to mention the ventilation) needed to ensure the safety of using the machine when it’s in use.

• It’s messy

This isn’t something you can quickly clean in 10 minutes. A silicone injection molding machine can cause lots of mess and it’s not that easy to clean. If your schedule is jam-packed, the last thing you want to spend your precious time on is cleaning a big machine you’re only going to use intermittently. Outsource your manufacturing and leave the dirty work to someone else!

So, there you have it. All the reasons why purchasing a silicone injection molding machine is actually a bad idea. If you have seen a company or an individual you’re going buy a silicone injection molding machine from, this article has hopefully given you pause to twice before that purchase. Outsource your silicone injection molding to professionals like us in order to save your time, energy, and money. Just ask us for a quote, we’ll be glad to help you with your project.

If you need help with that, or any other injection molding queries, please give us a call on 1.888.202.2052 or email jason@jcadusa.com. We’re here to help!

Jason Vander Griendt

Jason Vander Griendt is a Mechanical Engineering Technician with years of experience working at major companies such as SNC Lavalin Inc, Hatch Ltd. Siemens and Gerdau Ameristeel. He is the CEO of JCAD – Inc., a company he started in 2006 after seeing a gap in the market for businesses who could assist clients through the entire product design and manufacturing process.

Jason has been featured in Forbes, has had his businesses analyzed and discussed in multiple start-up books, was a previous winner of the Notable8 Digital Innovator of the year award, and is a regular guest on business panels and podcasts. Email Jason at jason@jcadusa.com or follow him on LinkedIn.

The post Silicone Injection Molding Machine For Sale? appeared first on J-CAD Inc. 1.888.202.2052.

There are a number of injection molding guidelines and best practices or principles to follow to ensure that you get the best results in your next injection molding project.

Injection Molding Design Guidelines include:

• Make sure you use uniform wall thicknesses throughout the part to minimize sinking, warping and residual stresses, and to improve the mold fill and cycle times.
• You are going to want to use generous radius’ at ALL corners. The inside corner radius should be a minimum of one material thickness.
• Be sure to use the least of the thicknesses compliant with the process material, or product design requirements. This ensures that the cooling process will be faster, the cycle times will be shorter, and the shot weight will be smaller. All of these will result in the least expensive part cost.
• Design parts to facilitate easy withdrawal from the mold, by providing draft (taper) in the direction that the mold is opening or closing.
• Use ribs or gussets to improve the stiffness of your part’s bending capabilities. This will help you avoid the use of thick section, but achieve the same strength and durability, and you’ll save on costs for part weight materials and cycle time.

Injection Molding Principles and Rules are as follows:

• Don’t forget the necessities of the process. There must be a location in the mold and on the part of the base material where material to form the part can be injected. This is referred to as a gate, and it must be removed from the finished part after it is formed, which can be done manually or automatically. The gate’s position is important, as you’ll typically want to position it at a thicker, intersectional area of your part. This is so that you may remove it without concern for its structural integrity.
• Consider your wall thickness. This is an important principle because some wholesalers/retailers will require a certain uniform wall thickness for your injection mold. And if you don’t meet the requirements, you won’t be able to sell your part or product. You can manage this by designing your part with manufacturability in mind.
• Incorporate a draft. Drafting your injection mold by adding a taper will result in a smoother removal of your part from the mold. It will also minimize any friction and scraping between the finished, cooled product and the walls of your mold. This makes the process run much more efficiently.
• Build in texture. Instead of adding a pesky second finishing process after injection molding, you can incorporate the finished pattern or texture right into your mold! You can achieve this by etching or milling the mold to create a finish. This will give you the greatest control over the finished look and feel of your part. Which will save time and money in the long run by reducing double handling.
• Know your materials. This is pretty self-explanatory. Simply make sure you are familiar with what you’re working with! Selection of your materials is a crucial aspect of the design process. If you choose the wrong materials, even by the slightest miscalculation, you could end up spending WAY more than you need too.

So there you have it, some guidelines and best practices for injection molding.

If all that information that seems like another language to you we’re here to help. Check out our injection molding information or give us a call on 1.888.202.2052 and let’s talk about making sure your next injection molding project is fulfilling the best design practices.

Learn more:

Where to buy injection molding machines

How much does a silicone mold cost to make?

Jason Vander Griendt

Jason Vander Griendt is a Mechanical Engineering Technician with years of experience working at major companies such as SNC Lavalin Inc, Hatch Ltd. Siemens and Gerdau Ameristeel. He is the CEO of JCAD – Inc., a company he started in 2006 after seeing a gap in the market for businesses who could assist clients through the entire product design and manufacturing process.

Jason has been featured in Forbes, has had his businesses analyzed and discussed in multiple start-up books, was a previous winner of the Notable8 Digital Innovator of the year award, and is a regular guest on business panels and podcasts. Email Jason at jason@jcadusa.com or follow him on LinkedIn.

The post Injection Molding Design Guidelines, Principles and Rules appeared first on J-CAD Inc. 1.888.202.2052.