The lead time of plastic injection molds is a complex process involving many steps and a large number of parameters. To understand the entire lead time, it is also necessary to identify the content of each of the described stages and the variables and difficulties that may be encountered. This article will explain these stages in depth and will also explain information related to the factors that affect the lead time and methods to enhance the lead time.

Complete Production Process of Injection Mold

Requirement Analysis and Project Planning

1. Requirement Analysis: The demand analysis process is the first step in delivering plastic injection molds. At this stage, it is necessary to understand the customer’s design requirements, functional requirements, material selection, demand quantity, quality standards, etc. in detail. Fully communicate and discuss with customers to avoid any misunderstandings during implementation. The accuracy and rigor of demand analysis determine the smooth progress of the entire project.

2. Project Planning: The detailed project plan is drawn from the results of requirement analysis According to this requirement. Project planning contains scheduling, assigning resources, planning for risks, etc It is the schedule of start and end time for each phase, and resources should be reasonable that comprises personnel, equipment, and materials, and the risk management plan should identify potential risks and develop countermeasures. Scientific project planning ensures the project proceeds smoothly as planned.

Mold Design

1. Preliminary Design: According to the set product design requirements, the preliminary design of the mold is carried out. It mainly includes mold structure design, cooling channels design, pouring system design, all of which must be taken into account in the mold. In the preliminary design stage, designers need to fully consider factors such as the product’s geometric shape, dimensional tolerance, surface quality, etc. to ensure that the mold design is reasonable and feasible.

2. Design Verification: After the preliminary design is completed, the preliminary design needs to be verified, usually using computer-aided design (CAD) software to check whether the designed mold is reasonable and feasible. The purpose of design verification is to discover and eliminate possible problems in the design to avoid major modifications to the mold in other stages.

3. Detailed Design: After the design verification is passed, the mold needs to be designed in detail. The detailed design includes all details of the product, such as the selection of mold materials and the size and tolerance of different components. The accuracy and quality of this step directly affect the manufacturing accuracy and service life of the mold.

Material Procurement

1. Material Selection: The mold material needs to be specifically selected according to the requirements of the mold design. Different materials vary in hardness, wear resistance, thermal conductivity, and other related aspects. Selecting the right material is crucial to the performance and life of the mold. Cost and supply conditions should also be considered for the material to be used.

2. Material Procurement: After the material is determined, material procurement is carried out. The procurement cycle generally depends on the supplier’s delivery time and material inventory. During the procurement process, it is necessary to maintain close communication with the supplier to ensure timely supply of raw materials.

Mold Manufacturing

1. Processing Preparation: Before mold manufacturing, certain processing preparation is required, including preparation of machines, tools, processing procedures, etc. The adequacy of processing preparation is also another factor affecting the mold processing effect.

2. Mold Processing: Mold processing is one of the most important processes in the entire delivery chain. Mold processing mainly includes milling, electro-etching, heat treatment and other processes. The accuracy and efficiency of each process in mold manufacturing directly affect the quality and delivery cycle of the mold. During the processing, various parameters in the processing process need to be strictly controlled to ensure the processing accuracy and surface quality.

3. Assembly and Debugging: After injection mold production is done the next steps are assembly and debugging. Assembly is the process of assembling the entire mold through connecting of various parts while debugging is the process of taking a total production of the mold to check whether it is functioning properly or the final product is being produced as desired. Careful operation is required during assembly and debugging to ensure that all parts of the mold fit well and operate smoothly.

Mold Verification

1. Mold Trial: Mold trial is required after the assembly and debugging stage. Mold trial refers to placing the manufactured mold on the plastic injection molding machine for trial production to evaluate the mold performance and verify the mold’s operating performance and product quality. During the mold trial, it is necessary to record the injection molding parameters, the quality of the produced product, and problem diagnosis.

2. Product Inspection: Products produced during the mold trial need to be inspected. Specific inspections include size inspection, appearance inspection, performance inspection, etc. Only after passing these inspections can the mold enter the next stage. The importance of product inspection is obvious, and it will directly affect the quality of the mold and customer satisfaction.

Mold Optimization and Improvement

1. Problem Analysis: In case of that, problem analysis is called for, should problems be identified during the mold trial. In general, the problem analysis includes mold structure analysis, processing analysis, material analysis, etc. This work aims to identify the root cause of the problem and form the basis for further improvement.

2. Problem Resolution: Based on the results of problem analysis, develop problem-solving solutions. Problem solving usually includes mold modification, reprocessing, material replacement, etc. When solving these problems, it is necessary to deeply identify the cause of the problem and the practical possibility of completely solving the problem.

Mold Acceptance

1. Mold Acceptance Standards: Mold acceptance has strict acceptance standards, including mold dimensional accuracy, processing quality, performance, etc. The formulation of acceptance standards should comprehensively consider customer requirements and the actual situation of the mold to ensure that the standards are scientific and reasonable.

2. Customer Acceptance: In the final stage, the injection mold manufacturer must hand over the mold to the customer for acceptance. The customer inspects the mold according to the acceptance criteria for mold design and quality to confirm whether the mold meets the requirements, which is also the basis for successfully delivering the mold to the customer.

Mold Delivery

1. Mold Packaging: After completing the acceptance requirements, the mold needs to be packaged. The packaging should ensure that it is not damaged during transportation. The selection of packaging materials and the determination of packaging methods should be determined according to the size, weight and transportation method of the mold.

2. Mold Transportation: The transportation method of the mold depends on the size, weight and destination of the mold. Special precautions must be taken during transportation to prevent the mold from being damaged during transportation.

Key Factors Influencing the Delivery Cycle

Design Complexity

The entire delivery cycle of a plastic injection mold, from the injection molding process and the selection of mold steel or aluminum mold, to the creation of the mold cavity and the completion of the entire process, depends on the specific requirements and complexities of the injection process.

The complexity of mold design has a direct impact on the design and processing stages. The complexity of the mold affects the design time and the time required for the verification stage, because complex mold designs require a lot of details, while relatively simple mold designs require shorter design and verification time. Complex mold structures require more time for processing and assembly, which will extend the delivery cycle.

Processing Equipment

Processing equipment will also affect the cycle of mold processing. Advanced processing equipment can improve processing rate and reduce processing costs. The automation level and processing accuracy of the equipment are also important. Modern CNC machine tools and automatic processing machinery can improve processing rate and reduce the possibility of errors.

Personnel Experience

The experience of the design and processing personnel is one of the main aspects that affect the delivery cycle. Strong designers usually need shorter design time and fewer design errors. Experienced processing personnel can also complete mold production more quickly. The experience and skill level of personnel directly affect the smooth progress of the project and the length of the delivery cycle.

Supply Chain Management

There is a connection between the delivery cycle of injection molds and the supply of mold materials and parts. A good supply chain can ensure the timely supply of materials and parts and avoid delivery delays due to lack of materials.

Quality Control

Maintaining strict quality standards can reduce errors and rework during processing, thereby improving productivity. Quality control involves many aspects such as design verification, processing monitoring, and product inspection.

Methods to Optimize the Delivery Cycle

Standardized Design

Standardized design can reduce design time and improve design efficiency. Standardized design includes the use of standard parts and standard structures in mold design and processing. The use of standardized design processes can shorten the design cycle and improve design quality.

Advanced Equipment

The use of advanced processing equipment and technology can improve processing efficiency and shorten processing cycles. For example: CNC machine tools, high-speed cutting and other precision processing equipment and various testing equipment.

Training and Management

Strengthening personnel training can improve the capabilities of designers and processing personnel. Improving project management can reasonably optimize time and resources at each stage. The effectiveness of project training and management can greatly reduce unnecessary expenses and extend project development time.

Supply Chain Optimization

An effective supply chain management system can ensure timely supply of materials and parts. Establishing long-term cooperative relationships with multiple stable suppliers is beneficial and can reduce supply risks. Optimizing and stabilizing the supply chain is essential to improving project execution efficiency and shortening delivery times.

Quality Assurance

Strengthening quality control can minimize errors and rework during processing. The application of various quality inspection equipment and high-tech methods can improve the accuracy and efficiency of inspection. Improving quality is a way to improve product quality and customer satisfaction and shorten delivery time.

Conclusion

The delivery cycle of injection molds includes several stages such as demand assessment, mold design, material procurement, mold manufacturing, mold identification, mold optimization adjustment, mold acceptance, and mold delivery. The time and quality aspects of each determined stage control the delivery cycle of the mold. By using advanced equipment to design more efficient molds, team training and management, supply chain management, and improved quality control, the mold delivery cycle can be effectively shortened, and the mold quality and customer satisfaction can be improved.

In actual applications, due to the differences in the actual conditions of various enterprises, it is necessary to flexibly apply various optimization methods, improve and enhance project management level, and achieve efficient mold delivery. It is not necessary to strictly follow any method. Only in this way can enterprises maintain competitiveness in the market and meet the market’s requirements for high-quality products and short delivery.