The Solution
D&M Plastics stepped in to assess the situation. Our experienced engineering and production team meticulously analyzed the existing mold, identifying several key problems:
- Loose Fit. The mold halves weren’t aligned properly, leading to parts with inconsistent dimensions.
- Poor Cooling. Inadequate cooling channels resulted in uneven part cooling and warping.
- Machining Marks. Surface imperfections on the mold transferred to the parts and affected quality.
- Design Flaws. The initial design lacked individual inserts for the four cavities, making repairs more complex and expensive. Additionally, the absence of a transition step between the straight sleeve ejector surface and the drafted molding surface allowed galling to spread from the ejector surface to the molding surface.
By implementing these changes, we were able to significantly improve the mold’s performance and extend its lifespan. The repaired mold now produces high-quality parts consistently, meeting the product distributor’s stringent requirements.