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.

1. Clamping: The two sides of the mold are closed and clamped shut.
2. 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.”
3. Cooling: The molten plastic that was injected into the mold is cooled and returns back to a solid state.
4. 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.

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.

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!

 

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.

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.

1. Market assessment: What problem in the medical industry is your device addressing? How is it different than other devices trying to address this problem?
2. Business model: How much will production cost? How will you sell it and who are your investors?
3. 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:

1. The ability to provide some utility
2. Needs to be novel
3. 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.

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?

1. Aluminum is easier to cut than steel which allows for faster machining and shorter lead times.
2. 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!
3. Aluminum cools at a much quicker and even rate than Steel. This reduces cycle time and saves money.
4. Since Aluminum is so light it can be machined on smaller equipment and also at a faster pace.
5. Aluminum dissipates heat at a very even rate, which allows for great dimensional stability due to less distortion.
6. 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!

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.

CNC machining stands for “computer numerical control” machining. It is a relatively new process in the world of machining which allows for increased efficiency through higher levels of automation and by allowing the machine and it’s computer controls to do all the work. While CNC machines are expensive and complicated, they quickly pay for themselves by reducing the workload and preventing errors.

The first major advantage of CNC machining is that it improves automation, removing the need of an operator for all but a few parts of the work. CNC machines can be left unattended for hours or even days if necessary, allowing operators to focus on other tasks. This also allows for a company to retain fewer operators, thereby saving on overhead. By removing the operator, safety is also increased, since should there be a jam or other potentially dangerous machining error, the operator will not be holding the tool and the only thing damaged will be the tool itself. CNC machines can also work much faster than human machinists, since they are faster, stronger, and do not need to take breaks. They can also be run late at night, when most of the workers have gone home, since machines do not need to worry about being sleepy or getting paid overtime.

The second big advantage to CNC machining is that it produces an exact result every single time. Even the best human operator will have minor variations between finished results, whereas a CNC machine will produce exactly the same result each and every time it is run. This is very important in the modern world of standardized and interchangeable parts, where a single defective cut can make an entire machine wholly unusable. All that is necessary is for a single program to be developed and placed into the machine. Then the machine can toil away at however many work pieces are needed, producing an exact replica down to thousandths of an inch each and every time.

The third big advantage to CNC machining is the flexibility of the machine itself. While humans are much more flexible and trainable than machines, a CNC machine can be completely reprogrammed in a matter of hours to produce a completely different product. It is thus possible to refer back to old programs or install new programs when a different work piece is required. This gives CNC machines a big advantage over other machines, since they can quickly shift to producing a completely different product without the installation of many new parts or a major overhaul of key components. This also ensures that CNC machines can keep up with customer demand, since they can very quickly shift from making a part that is in surplus to a part that is lacking should a need arise.

To learn more, check out this great resource for CNC Machining.

Whatever the item a person or a company intends to produce, creating a prototype is a crucial step in the design process that cannot be glossed over. Why is prototyping important? There are several main reasons; testing and evaluating the design, clarifying production issues and costs, selling it to others, as well as making clear any patentable details.

Evaluating and Testing the Design
Unfortunately, ideas and drawings of a design can sometimes be a far cry from the real world in which the product will be used. By creating a prototype it is possible to sit down with a real version of the product and determine which aspects are worthwhile and which parts need to be revised, changed, or discarded. In the process, it may be possible to find glaring omissions that, on paper, weren’t noticeable.

Additionally, creating a prototype will allow the design team to not only evaluate, but also test the product before going into full production. Imagine ordering tens of thousands of units, only to discover one part isn’t as strong as it needs to be. If corporate giants can make mistakes, it is all the more important for smaller companies to not forget the importance of prototyping before beginning production.

Clarifying Production Costs and Issues
Once production begins, it is costly and time consuming to make changes. By prototyping before production begins, it is possible to take a glimpse at the production process and see if any steps can be changed, combined, or even removed. This not only streamlines production, but keeps the?cost of the actual production to a minimum. Subsequently, if there are any difficulties in production or perhaps processes that can create problems for the final product, it is much better to see these before production starts. It can also help the design team ascertain the optimal method for production; injection-molding, silicone molds,?stamped metal, etc.

Selling the Product to Others
Just like it is far easier to see if there are any problems with a design by holding an actual working model, it is also far easier to sell to potential customers when they have a prototype to hold and manipulate at a marketing presentation. Without a prototype it’s only a concept. It can be difficult to get a?client to commit to a purchase of a concept. With a prototype in hand, the concept instantly becomes real and it is far easier to sign a purchase order.

The customer needs to be taken into consideration during the prototype phase as well. No matter how great the designers and testers think a prototype may be, real consumers may not like certain aspects of it. If the end customer doesn’t like it, they won’t buy it, which is why focus groups and external testing with prototypes needs to be addressed before production begins.

Patents
If a product is new enough or unique enough, patents need to be considered. It’s no use to design and manufacture a great product only to have another company start producing a remarkably similar product because the original company failed to patent key aspects of the design. By having a working prototype, it is much easier to sit down with a patent attorney and see what design aspect may be patentable. On the reverse side, it is possible to see what parts of the prototype and design violate patents of other individuals and how they can be changed before production, and the chance of a lawsuit, begins.

Contact TenX today and get a high-quality prototype fast! 715 235-8474.

Rapid Prototyping is a term used to describe many manufacturing processes that are able to quickly convert 3D CAD models into physical parts. Some of the technologies used in rapid prototyping are stereolithography (SLA), CNC machining, urethane casting and quick-turn tooled injection molding. Many of these rapid prototyping processes produce parts that are at or near production quality, which can be very beneficial at many points during product development.

The greatest benefit of rapid prototyping is the ability to test various part concepts quickly. Even the best engineers and designers are regularly surprised by what can be learned by evaluating and testing a representative part. Details that may not be apparent on a CAD system or on paper will show up readily in a rapid prototype. This eliminates costly mistakes, improves the quality of the design, and allows more valuable iteration cycles of concept to prototype.

Rapid prototyping is often a very low cost option for constructing prototypes, especially when the cost of the time to manufacture a prototype using more traditional methods or waiting for first tooled pieces is factored in. While the cost for rapid prototype parts is almost always higher than production parts, tooling outlays are minimal. When it is time to move to production tooling, rapid prototyping will likely have minimized mistakes that would otherwise have resulted in costly tooling revisions or remakes.

Rapid prototyping also provides the opportunity to conduct market studies with prototypes that have a realistic look and feel. Gaining early data on how the market accepts or reacts to the product is valuable information which can be used to improve the design and ultimately increase sales.

Product development is often very sequential, but rapid prototyping places efforts in parallel. Once a design has been completed, rapid prototyping can be used to push a product to market quickly capitalizing on any window of opportunity while long lead-time tooling is underway. This yields greater control over a product’s launch and early market adoption.

Rapid prototyping should be an integral part of almost any modern manufacturing organization’s new or sustaining product plan. The benefits of speeding iteration, improving design quality, lowering costs, providing a tool to evaluate the market, and going to market quickly provide more efficient development cycles which will result in better products with better profits and revenues.