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Resin Types: ABS vs. HDPE vs. TPU Injection Molding
Acrylonitrile butadiene styrene (ABS), high-density polyethylene (HDPE) and thermoplastic polyurethane elastomer (TPU) are commonly used thermoplastic polymers — a plastic material that becomes pliable or moldable at an elevated temperature and solidifies once it has cooled — used in injection molding projects.
Considering the benefits of ABS, HDPE and TPU injection molding can help you determine which are the best injection molding materials to meet your project needs.
ABS Injection Molding
ABS injection molding is often used to manufacture sporting goods, medical devices and industrial applications. So, how do you make ABS plastic molds? It’s easy to get the raw materials for, is considered to have good overall performance, it’s inexpensive, and ABS is among the most common plastic resins used for injection molding manufacturing.
A commodity resin, ABS is a suitable choice for producing inexpensive and strong plastic that will hold up against external conflict. ABS injection molding is resistant to humidity, temperature and frequency of use, making it a top choice among injection molding materials. It’s even resistant to most oils and acids, making it popular for furniture, packaging and toys.
ABS is a top choice in 3D printing and is the standard injection molding method for making prototypes.
HDPE Injection Molding
HDPE injection molding is made from the polymerization of ethylene. Its strength-to-density ratio is superb, designating it a standard choice in the manufacturing of water bottles, milk jugs, plastic envelope mailers, piping and food storage containers.
Another inexpensive commodity resin, HDPE plastic for injection molding is melted into a moldable state and is then transferred into the cavity of the mold once it has reached the correct temperature to meet your HDPE injection molding needs. Note that as soon as it’s in the cavity, it begins hardening quickly. HDPE is popular for its customization control and is among the most efficient choices for injection molding manufacturing.
TPU Injection Molding
TPU injection molding is best suited for applications that require the elasticity of rubber with high tear strength. TPU is elastic, can be painted, performs well at high temperatures, and is resistant to water, fuel and chemicals. TPU also needs little or no compounding.
TPU injection molding is popular in the manufacturing of sporting goods, medical devices and is a favorite for use in automobile manufacturing. An engineering resin, TPU is pricier than working with ABS or HDPE.
Glass Alternative Resin
There’s another injection molding resin type you may want to look at if you require an alternative to glass: polycarbonate injection molding. Polycarbonate is a lightweight resin that is pliable and has a natural UV filter.
An engineering resin, polycarbonate is an amazing alternative to glass, as it’s transparent and resistant to cracks and breaks. From manufacturing light fixtures to eyewear and medical devices, polycarbonate injection molding is a popular resin type. However, polycarbonate is not always preferred, since it’s prone to scratching.
Want to learn more about ABS, HDPE, TPU or polycarbonate injection molding, or ready to get started on your own injection molding prototype? Contact our experts to start your project today!
Comparing Insert Molding vs. Injection Molding
Injection molding is a subset of the injection molding process. An accomplice, if you will. When determining whether insert versus injection molding is what’s needed in the manufacturing of your products, it’s helpful to have a basic understanding of each process and how they can help make the products you need.
Understanding the benefits of insert molding versus injection molding will increase efficiency, production, and save on your bottom line in the manufacturing of your products.
Behind Injection Molding
Clamp down. Injection. Cool off. Ejection. That’s the never-ending cycle of injection molding.
Injection molding is a manufacturing process used to produce parts by injecting molten material into a mold that has been carefully assembled to meet the needs of a specific design, such as an overhead locker door for a jet airplane, or part of a toy set.
This process can be achieved with a variety of materials, such as plastics, and the material is fed into a heated barrel and then shot into a mold cavity, where it will quickly cool and harden into the object it’s meant to become. Then the item is removed from the mold cavity and the process continues on, as more and more items are manufactured.
The prototype injection molding process at TenX starts with plastic material being forced into a mold cavity under pressure. Pelletized resins, as well as any required colorants, are fed into an injection molding machine. The resins and colorants are inserted into an injection barrel where they are heated and melted, then forced into the mold cavity where it cools. Overall, it’s a process which is very fast and easy to repeat with predictable outcomes which help streamline your manufacturing process.
How Insert Molding Contrasts Versus Injection Molding
Insert molding is the process in which thermoplastic material is molded around a preformed insert to make a part that includes multiple materials. The inserts are often metal parts used to reinforce mechanical properties that are part of a plastic item. Inserts are placed into a mold, and then the thermoplastic is added to create the part.
Insert molding products include medical devices, electronic components and consumer products. It’s also common for insert molding products to be components under the hood in automobiles, and they are also incorporated in aerospace design and on aircraft. When determining which insert molding products you can make, note that most thermoplastic resins work well within the insert molding process.
Final Thoughts: Insert Molding Versus Injection Molding
An advantage in utilizing insert molding versus injection molding is it’s quick and cost-efficient as it helps speed up the manufacturing process. When determining to go with insert molding versus injection molding, insert molding has become increasingly common in the manufacturing of products, since the combination of plastic and metal blends the function and convenience of the lighter-weight plastic with the strength and endurance of the metal.
Ready to get one step closer to completing your insert or injection molding prototypes? Our expert team is here to help. If you have any questions about how we work, or the services we can provide, reach out to our team.
Improve Your Medical Injection Molding Validation Process
The procedure for validating the medical injection molding process is critical to verify that the system offers repeatability, assurance of accuracy, and a high degree of quality. It’s important to receive validation for medical injection molding so it’s consistent and traceable. To meet these requirements, manufacturers use a three-step validation process described as:
- Installation Qualification (IQ)
- Operation Qualification (OQ)
- Performance Qualification (PQ).
These procedures help qualify Tooling, Materials, Equipment, Systems and Processes. The goal is to validate that the entire life cycle of the medical injection molding process is repeatable and traceable with a high confidence level that the quality repeats from lot to lot and year to year.
The Medical Injection Molding Process
There are four major variables that control the process: melt temperature, fill speed, pack pressure and cooling rate.
- Melt Temperature: The temperature at which the polymer will begin to melt
- Fill Speed: The time it takes to fill the mold with polymer
- Pack Pressure: The pressure applied to the melt to pack in the polymer and to force more of it into the mold
- Cooling Rate: When there is no more pressure being applied, how long it takes for the melted polymer to cool
Three of the variables are easy to duplicate from run to run. However, measuring melt temperature has always been a mystery, as it is difficult to measure accurately. Molders agree that melt temperature measurement remains one of the “last frontiers” of medical injection molding process control.
“You can’t control what you can’t measure” is a fundamental axiom, and the problem here is the lack of an accurate, repeatable, practical, and generally accepted method of measuring the melt temperature.
Why is it important to control melt temperature?
Melt temperature influences the plastic’s viscosity or resistance to flow (thinness or thickness), which is critical in obtaining optimal part dimensional control. Consistent viscosity allows for repeatable filling of mold with consistent cavity pressure, and less part to part and lot to lot variation. You will get a tighter “bell curve” on dimensional variation.
A revolutionary new system has been in development for the last 4 ½ years called the Melt Temperature Measurement System (MTMS). There are two major principles that define the system.
- An insulated cup is used to keep the purge molten so it can be measured before it solidifies.
- There is a defined flow path in the system that forces the molten material over the thermocouple probe.
A high-speed pyrometer records the peak temperature. It is fast, repeatable and easy to use. Gage R&R studies have been successfully completed.
Start Validating Your Medical Injection Molding
OEM Medical Companies should ask in-house molders and contract molders if they are monitoring and documenting melt temperatures. Contract or custom molders should be monitoring and documenting melt temperature as a Standard Operating Procedure (SOP) to improve your medical injection molding validation process.
Do you know your Melt temperature?
A Guide to Improving Your Plastic Injection Molding
Plastic injection molding is one of the most common manufacturing processes because of its ability to produce identical parts at a rapid rate. Almost every industry has some demand for plastic injection molded parts; a wide variety of consumer products are manufactured by injection molding, which varies greatly in their size, complexity, and application.
The plastic injection molding process requires the use of an injection molding machine, plastic resin pellets, and a mold. The plastic resin pellets are melted in the injection molding machine and then injected into the mold, where it cools and solidifies into the final part.
Our variety of press sizes ranging from 7-500 tons allow us to meet your injection molding needs in both prototype and production volumes ranging from 100 to 1,000,000+ parts. This allows us to produce quality plastic injection molded parts while cutting down time to market.
We offer both overmolding and insert molding, both of which are standard injection molding processes.
Overmolding involves two or more materials molded together to become one part. Most commonly when a substrate is placed into the mold and plastic resin is then overmolded around, over, or through it.
Insert Molding involves a preformed part, such as a metal insert to be inserted in the mold for injected plastic to flow around, over, or through it to result in a single molded plastic piece which has encapsulated the insert.
We’ve put together some commonly asked questions about plastic injection molding, so that you can find out if it is the best process for your product.
Why Choose Plastic Injection Molding?
Injection molded parts offer incredible accuracy and repeatability at a cost-efficient price point. Plastic injection molding is also a very efficient way of producing parts; cycle times can range from a few seconds to a couple of minutes depending on the size of the part and the number of cavities in the mold.
There are numerous materials available that offer different, unique characteristics that fit a wide range of applications. At TenX Manufacturing, we use pelletized resins and as well as any colorants required. The parts can be completely customized with molded-in inserts, custom colors and branded logos. Once plastic injection molded parts are removed from the mold, they are a finished product with the exception of a few post-process steps like sonic welding, UV laser marking/pad printing, or further part assembly.
What is plastic injection molding used for?
Injection molding is used by almost every industry, the majority of plastic products in the world today are injection molded parts. Consumer products like cell phone cases, implantable medical devices, automotive parts, and so many more are examples of how injection molding is integrated into everyday life.
We currently have a shot size range of .152oz – 54oz, so we can produce plastic injection molding parts within these sizes for any industry.
What material are injection molds made of?
There are many factors in determining what kind of mold should be built (prototype, production, single-cavity, or multi-cavity) and most are typically made from aluminum or tool steel.
For building aluminum injection molds, the most commonly used grade of aluminum is 7075; these aluminum molds are typically a great fit for prototype or short-run production. Steel tooling is commonly produced from tool steel in the following grades: P20, H13, A2, D2, and 4140. These steel molds are a great fit for high-volume injection molding or when molded parts are being produced from abrasive material like glass-filled nylon.
Why are injection molds so expensive?
Building an injection mold is a lengthy and potentially expensive process that starts with an understanding of the part that needs to be molded. Potential plastic injection molding problems can be minimized by performing upfront precautions like mold-flow simulations, fill and warp analysis; these measures can highlight potential issues and save time & money down the road.
The block of material, whether aluminum or steel from which the mold will be made, is also a determining factor in the cost of injection tooling. Part geometry and number of cavities will directly correlate to the amount of CNC machine time that is required to make the mold. Parts that have complex geometries (undercuts) that require any additional movement in the tool other than open or close will add to the complexity and cost of the injection mold tool.
How to Optimize the Plastic Injection Molding Process
Optimize the Part Design for Injection Molding
Having a part properly designed for prototype injection molding is critical to achieving manufacturing success. Things to consider include:
- Material
- Wall thickness
- Draft
- Undercuts
- Gates & gate locations
- Part ejection
- Texture
Utilizing software such as Mold-Flow Simulation & Warp Analysis is extremely beneficial and can highlight potential issues prior to building an injection tool.
Understand Common Plastic Injection Molding Part Defects
Understanding the injection molding process as well as the common defects that can happen to injection molded parts:
- Warp
- Flash
- Sink
- Knit lines
- Splay
- Burn marks
- Short shot
- Air voids
- Material degradation
Although some of these defects can happen from improper injection molding processing, properly designed parts and injection mold tooling can minimize these from happening.
Correct Injection Mold Processing
The plastic injection molding cycle occurs by melting plastic resin pellets and injecting the molten material under pressure into a closed metal mold tool. This process is repeated time and time again to produce large quantities of parts at a cost-efficient rate.
- Clamping: The two sides of the mold are closed and clamped shut.
- Injection: The plastic resin pellets are fed into the machine and pushed towards the mold. While this is happening, the material is melted by heat and pressure. The molten plastic is then injected into the mold — this is called the “shot.”
- Cooling: The molten plastic that was injected into the mold is cooled and returns back to a solid state.
- Ejection: Once the part has cooled, it is ejected from the mold.
This is a complex process and it takes numerous pieces of equipment and highly trained individuals to oversee the entire process.
Perfect the Process With a Melt Temperature Measurement System Kit
If you do choose to do your own plastic injection molding, you’ll need to be able to accurately measure melt temperatures. Equipped with accurate measurements, you’ll reduce wasted material and minimize variation from lot to lot, saving you more time and money. TenX offers a Melt Temperature Measurement Kit that helps you eliminate human error in a safe and effective way.
If you’re in need of a prototype or have any additional questions about plastic injection molding or the process, our team at TenX is here to help. Contact our shop and get started on your plastic injection molded part.
COVID-19 Update:
In these unprecedented times, Schmit Prototypes is implementing a NO VISITOR POLICY for our OFFICE due to the spread of the COVID-19 virus. We appreciate your understanding and look forward to welcoming our guests back to our office once things stabilize.
In the meantime, our team is committed to working with you via phone, email, and Webex to respond to quote requests, order status, and other customer service-related requests.
We are operating at normal capacity in our shop and will continue to do so for the foreseeable future. Our employees are practicing great protection and prevention methods. Our dock is actively receiving and shipping orders. We are here to support our customers, employees and our community.
Prototype Development for Electronic Enclosures
All electronics have one thing in common — they are vulnerable to the elements. Moisture, dust and any other debris can quickly turn a useful product into a useless paperweight. Your customers understand the fragility of any electronic product and will naturally prefer items that are well-built, sturdy and attractive. It takes a solid enclosure to ensure predictable functionality along with eye-catching visual appeal for your product.
Even if your circuit board is working without failure during development, real-world scenarios quickly take a toll on any electronic device. Our team can work with you to bring your vision to life and create a product casing that stands up to regular wear and tear. Our engineers are experienced in product design and will help you create a visually-appealing casing that catches the attention of potential customers. Wondering what goes into that process? Our prototype development process couldn’t be easier, so read on to see how it all works.
Assess Prototyping Stage
The price of your project largely depends on the type of process we use to assemble your prototype. From the very beginning, we take your unique budget needs into account to move forward with the most practical prototype we can create. Our goal is to meet your needs while never overcharging for any of our services.
A prototyping budget typically varies by stage. In the first stages of prototyping, you’re not going to want to invest too much money into prototypes that may or may not lead to the final product design. Your electronics concept may make sense on paper, but creating effective electronics housing sometimes takes a trial-and-error approach. 3D printing is ideal in these scenarios, as it is a low-cost and rapid form of prototyping.
On the other hand, if you’re further along in your prototyping, with several iterations already completed and tested, it may be time to move to a process more closely resembling the final product. A service such as injection molding creates prototypes with the functionality and aesthetics that closely match your vision for the consumer-ready version.
Choose a Material
The material you choose to build a prototype with is as important as the shape of the prototype. For that reason, it’s essential to consider the exact properties you expect out of your product type, as well as the final design. Are you looking for moisture resistance? How about a translucent material? These are the questions any product designer should ask themselves before moving onto prototyping. The TenX team can provide you with the materials it takes to create a product with the exact characteristics you have in mind.
Think about the types of priorities that matter most for your product:
Some electronics enclosures require a combination of characteristics, so it can be difficult to know the exact material your product needs. Our prototyping experts are available to provide guidance no matter what stage you are at in your prototyping process.
Consider Smaller Details
If your electronics enclosure features multiple or connected parts, it’s going to take additional fasteners, brackets, hinges or another type of accessory to bring it all together. At TenX Manufacturing, we can provide you with the features it takes to create the functionality you envision.
For example, our 3D printing services are ideal for manufacturing threaded fasteners, snap-fits, interlocking joints and threaded fasteners. If your prototype requires CNC machining, a press fit may be a better option. You can rely on our expertise when you need guidance on design details that are easy to overlook.
Get Prototyping
Ready to get one step closer to your final electronics product? We are here to help. If you have any questions about how we work or the services we can provide, don’t hesitate to reach out to our team. We look forward to providing the enclosure solutions you’re looking for in your prototypes!
How Prototypes From Aerospace Engineering Make It in the Sky
The aerospace and defense industry experienced an 8.6% increase in revenues from 2016 to 2017, according to a Deloitte financial performance study. And the industry plans to see higher gains as innovation persists. In fact, both Uber and Boeing are making a push to design air taxis used across the United States within the next decade.
The growth in this industry is going to make prototypes from aerospace engineering more and more prevalent.
Why Prototyping Is Necessary With Aerospace Engineering
Prototyping is necessary for the aerospace engineering industry because various prototype processes use materials that lighten an aircraft’s payload. This ultimately leads to savings on fuel and emissions and enhances the speed and safety of the aircraft. Prototyping also gives engineers design freedom and rapid, predictable outcomes when they manufacture the same part over and over again.
How Prototyping And 3D Printing Helps Aerospace Engineers
The introduction of 3D printing in the aerospace industry has revolutionized the way engineers approach aircraft design. Much like the progress in the medical industry, new part design starts digitally with computer-aided design (CAD) and drafting (CADD).
Graphic designers have thrived with 2-dimensional designs through various computer software. Engineers now have the same capability with their 3-dimensional part by bringing their work to life digitally before moving to the prototyping process. These CAD files store vital information such as measurements and flexibility of a part before it’s created through 3D printing.
Once the 3D print has been created, engineers will put it through benchtop tests. If the part fails, the prototype will be sent for an iterative redesign. The CAD file helps the engineers identify the data point on the design that failed. Once the part is reworked, the history of the change can be saved in the CAD file so the old characteristics can be housed if the engineers ever need to go back and tinker with another data point of their prototype design.
Scaling the prototype is another advantage 3D printing offers. The automatic, computer-generated part will form the exact measurements for the part every time, so the new design is consistent for manufacturers.
The Role of Injection Molding in Aerospace Design
Injection molding is when the palletized resin is put under substantial pressure within a state-of-the-art machine and is formed in a molded cavity. This customized molded plastic can be shaped to perform vital tasks within an aircraft. Injection molding specialists can work in lockstep with aerospace engineers to ensure the specifications of the part are perfect and use the mold to repeat the new design for mass production.
Prototype Examples That Can Be Used in the Aerospace Industry
Innovative prototypes from aerospace engineering workshops are already in flight today. 3D printing is already being used to produce specific aircraft interior components such as air ducts, armrests, seat end caps, seat framework and wall panels.
NASA has been in the 3D printing business for nearly 10 years. As early adopters of the technology, they 3D printed flame-retardant vents and housings for their Mars Rover. They also used 3D printing for camera mounts, pod doors, the front bumper and other parts of the Mars vehicle.
Prototyping will be an integral piece of the manufacturing and new part development processes for years to come. The prototypes from aerospace engineering will without a doubt be at the center of space exploration as well as the coming transportation revolution.
We’re committed to that future and can’t wait to play our role. You can learn more about what we do and discover for yourself how we can help the aerospace industry continue its innovation.
How Medical Device Development From Prototype to Regulatory Approval Works
Many inventors and physicians have experienced an “ah-ha” moment. The stars align and they’re ready to present the world with a great idea, and potentially make a lot of money selling it from hospital to hospital. However, it’s not as simple as grabbing some material and going to your garage.
First, you need to understand how medical device development from prototype to regulatory approval works.
The path to commercialization of a medical device is long, expensive and takes an engineering mindset. Here are the phases you must pass through to have your medical device breakthrough hit the open market.
Phase 1: Initial Ideation and Getting a Patent
Phase one of the medical device development process is a more extensive deep-dive into defining your new invention. The best way to accomplish this is by answering questions about 3 main pillars in trying to sell a brand new product in the healthcare industry.
- Market assessment: What problem in the medical industry is your device addressing? How is it different than other devices trying to address this problem?
- Business model: How much will production cost? How will you sell it and who are your investors?
- Engineering: Are you using existing technology to develop this product? Are the components available for you to use or do new components need to be manufactured to help create your invention?
New medical inventions also need to meet the right classification by the Food and Drug Administration (FDA). There are 3 classes based on the potential harm a device can have on a user. Depending on the class, some devices may take longer to become market-approved than others. Luckily, the FDA provides a thorough guide for classifying your device.
Does your device already have a patent?
At this point in the process, you have a pretty good idea of what steps you will need to take to turn your dream device into a reality. Before you get your hopes up, an essential step is getting a patent.
Patents aren’t handed out once a prototype is built. Patents are used to exclude others from creating your product. So, in theory, people have received a patent for something not yet available on the market. They’re essentially patent squatting.
To get a patent your idea needs 3 things:
- The ability to provide some utility
- Needs to be novel
- The person needs the skill in that area of invention
Applying for a provisional patent before developing your new device will help give you time — and the right — to develop your invention.
Phase 2: Research, Discovery & Prototyping
The digital era has made it easier for inventors and manufacturers to work in lockstep with each other when creating a design for a new part. While hard, paper copy blueprints may still exist, 3D CAD files allow product development and research to move at a much faster pace.
You can buy software to build and examine CAD files or you can work with a prototyping company that gives you access to this convenient technology.
These CAD files will allow you to focus on the function of your design, not necessarily the design and how it will look. Once you pin down the functionality of the device, you need to utilize the most practical method for prototyping your new medical device.
What kind of prototyping does your medical device need?
After researching and discovering the best way to create your part, you need to bring it off the computer screen and into something tangible. This is called prototyping and there are several methods.
- 3D Printing: Great functionality and already doing wonders in the medical community
- Injection Mold Tooling: Used to ensure all the parts will fit together in your new device without wasting resources on the material you will use
- CNC Milling: Makes extremely accurate parts for designs that have specific angles and provides a fully-functioning part you can test
- Casting: Makes your part flexible so it can replicate the bend and twist you will ask the final part to perform
Creating your first prototype will be an exciting experience as you see your invention come to life. But making a life-sized model will also highlight the deficiencies with your design. This means a redesign and proof-of-concept will be needed.
Phase 3: Proof of Concept and Redesign
During the medical device development process, proof of the part’s functionality is needed before it can be sent anywhere to get approved. These tests generally happen with the engineers at the test bench. Here is where they verify the correctness of the device’s design by simulating its use.
For example, something like the Sapien transcatheter aortic valve — used as an alternative to open heart surgery — needed to be planted in a simulated heart during the POC testing phase. If it doesn’t pass testing, another round of design is needed.
The iterative redesign process
The iterative redesign process is initiated when a prototype fails a benchtop engineering test. The iterative redesign accounts for the failure of the prototype and identifies data points to build a better holistic perspective on the medical device and the intricacies it may have. It’s also less expensive to initiate a redesign at the prototype level rather than making a change once the completed part is built.
By gaining an understanding of the device’s characteristics through the iterative redesign process, the inventor can determine the viability of device commercialization.
Phase 4: Market Approval Steps
The steps for market approval are established by a quality management system (QMS) which provides a framework to ensure your medical device is legit through policies and development procedures.
The QMS is regulated by Good Manufacturing Practices to guide the device’s development process and create a design history file (DHF). A DHF documents when a part was tested and provides background information about the design and manufacturing process. The DHF is created so the FDA can audit the process to ensure it is safe and effective for users of the new medical device.
Once the DHF is completed and the FDA testing requirements are met, you need to submit your device for regulatory clearance. The DHF will prove to the FDA your medical device is safe, and then you can begin to market and sell your product.
For a more thorough evaluation of the FDA certification process, you can find their medical device development process on their website.
If you’re ready to take your first steps toward your entrepreneurial dream, consider partnering with TenX. We offer the capabilities and industry know-how to get your medical invention out of your head and into the hands of patients who need it most.
Aluminum vs Steel Tooling
Have you been looking for an alternative to traditional steel molding? Are you interested in reducing cycle time and costs? Aluminum tooling may be the answer for you. Aluminum tooling has many benefits that make it a viable option these days. What are these benefits?
- Aluminum is easier to cut than steel which allows for faster machining and shorter lead times.
- Although Aluminum is perceived to be too soft for high volume production, this is simply not true. Some Aluminum molds are capable of producing parts after 2 million cycles!
- Aluminum cools at a much quicker and even rate than Steel. This reduces cycle time and saves money.
- Since Aluminum is so light it can be machined on smaller equipment and also at a faster pace.
- Aluminum dissipates heat at a very even rate, which allows for great dimensional stability due to less distortion.
- There is far less scrap because there is far less cracking and warping.
Aluminum is often looked at as weak, soft material that is no good for high volume production. However, Aluminum can in fact be used for high volume. It can also be machined faster and dissipates heat at a much quicker, even rate than Steel does. As a result of this, often times lead times are shortened and money is saved. Who doesn’t want to save money?
As for the longevity of Aluminum tooling, surface coatings can extend the already impressive life cycle. Many companies are now using Aluminum for production instead of just prototype work.
TenX Manufacturing offers low-cost aluminum and steel tooling. Most of our inserts are created using Aluminum. Our in-house capabilities allow for aggressive lead times on tooling and a quick response to tool modifications.
Our knowledge of the benefits of Aluminum tooling has helped our customers save time and money. Give us a call today to find out if Aluminum tooling can do the same for you!
Benefits of Stereolithography
Stereolithography (SLA) is an additive process that uses a vat of liquid UV-curable photopolymer resin and a computer controlled UV laser to build parts one thin layer at a time. The UV laser cures, or, solidifies the part layer and adheres it to each additional layer.
After each layer has been cured, the SLA machine lowers the platform by a single layer thickness, typically 0.002″ to 0.006″. A resin filled sweeper blade then moves across the cured layer recoating it with another layer of uncured resin. Each layer is cured by the laser, curing it and adhering it to the previous layer. This process repeats until the 3-D part is completed. Once complete, the SLA machine raises the platform from the vat of resin and the part can be removed, cleaned and final cured in a UV “oven”.
One advantage of stereolithography is that a functional part can be built in a relatively short period of time. The amount of time required depends on the size, complexity and layer thickness the part will be built with. Parts can take anywhere from a few short hours to a day or more. Parts built with an SLA machine can be used as master patterns for RTV molding, finished and painted or simply lightly sanded and may be used for shape studies or final presentation models.
The Stereolithography process can help you decrease costly mistakes by detecting design flaws before the manufacturing process. It can be a cost-effective option for low-volume production and also provides quick lead times.
Contact TenX today and get a high-quality prototype fast! 715 235-8474.