Design & Engineering-Shenzhen JTO Electrical Co. Ltd.

Injection Mould Design & Engineering

Lyter’s tooling design and engineering team has over 16 years experiences in mold making industry.

The team member includes experienced product and plastic injection mould design engineers, as well as mould making technicians with excellent craftsmanship.

With years of tooling design and manufacturing and cooperation with reputational companies, such as GE, Whirlpool, Honda etc. from automotive and appliances industry, the company now has developed an effective management system to bring our values and expertise to meet customers satisfaction.

Our engineering department has 28 employees, include 22 engineers and 6 technicians, half of them has a good understanding of technical English, can read, write, listen and speak to customers fluently without language barrier. Our team has capacity to support your product design & development from very early stage to the production end.
Injection Mold DFM Report Submission and Approval

For every plastic injection mould project, Lyter will provide a detailed DFM report to carry out the research on part visible area specifications, parting line on major and important mold inserts, the mold layout and basic sizes, the mold ejection layouts, gate details, draft the thickness analysis, cooling channel proposal for cavity inserts and critical areas, improvement proposals and product engraving specifications etc. We start to design the plastic injection mould after DFM approval by customer.

The DFM (Design For Manufacture) Analysis Report allows both customer and us to identify and fix any issues that might happen in the tools manufacturing phase to save timing and costs.

Normally it takes 1-2 working days to finish the DFM for a normal injection moulds DFM. If there is special urgency need, customer can feel free to discuss with us and we will move quicker to support.
Moldflow Rheological Analysis

Our Moldflow Analysis includes

Plastic Material Analysis
Wall Thickness Analysis
Feed System Analysis
Processing Conditions
Filling Process
Filling Time
The Pressure at V/P Switchover
The Temperature at the Flow Front
Sink Marks Estimate
Average Volumetric Shrinkage
Weld Lines
Defection—X, Y, Z—direction
Air Traps
Injection Pressure & Clamp Force

MoldFlow report will be provided when it is required or necessary. By iterating the simulation of molding, we can optimize product design and the mold design, to get rid of unnecessary modifications to both part and the mold, saving costs and timing for the project.

CASE STUDY

What should we pay attention to for Hot Runner Mold Design?
What Are the Key Points for Mould Design?
Mold & Part Design Keypoints-Automobile Lamp Products-a
Mold & Part Design Keypoints-Automobile Lamp Products-b
Mold & Part Design Keypoints-Automobile Lamp Products-c
Mold & Part Design Keypoints-Automobile Lamp Products-d

1.To determine the gate location according to the plastic part structure and usage requirements. As long as the structure allows, the nozzle and nozzle head in the fixed mold insert does not interfere with the molding structure, and the gate of the hot runner system can be at any position of the plastic part. The position of the injection gate for conventional plastic injection molding is usually selected based on experience. For large and complex special-shaped plastic parts, the position of the injection molding feed inlet can be simulated by computer-aided analysis (CAE) to simulate the flow of molten plastic in the cavity, analyze the cooling effect of each part of the mold, and determine the ideal gate location.
2.Determining the nozzle head form of the hot runner system. Product material and use characteristics are the key factors for choosing the nozzle head form, and the production batch of plastic parts and the manufacturing cost of the mold are also important factors for choosing the nozzle head form.
3.The number of cavities per mold is determined by the production batch of the product and the tonnage of the injection machine.
4.The number of nozzles is determined by the position of the glue inlet and the number of cavities per mold. If you form a product, choose one mold and one feed inlet, you only need one nozzle, that is, use a single-head hot runner system; if you form a product, choose one mold with multiple cavities or one mold with one cavity with more than two feeds If you want to open the nozzle, you need multiple nozzles, that is, a multi-head hot runner system is used, except for the mold structure with a cross runner.
5.To decide the radial size of the nozzle accords to the weight of the plastic part and the number of nozzles. At present, the nozzles of the same form have multiple size series, which meet the requirements of forming plastic parts in different weight ranges.
6.Deciding the mold structure size according to the plastic part structure, then select the nozzle standard-length series size according to the thickness of the fixed mold insert and the fixed template, and finally trim the thickness of the fixed template and other dimensions related to the hot runner system.
7.Confirming the shape of the hot runner fixing plate according to the shape of the hot runner plate, arrange the power cord lead groove on the plate, and design an adequate cooling water loop near the hot runner plate, nozzles, and nozzle heads.
1. The overall layout of the mold is reasonable
2. Parting surface selection
3. Layout of 3 runners, selection of glue inlet
4. ejection device
5. water transport arrangement
6. exhaust options
7. Pay attention to the draft angle when parting the mold, the extraction of inserts, the treatment of the rubbing angle, and the selection of material shrinkage
8. Processing drawings should be detailed, but simple.
All in all, mold design must consider the ability to demould! Easy to process and to eject!
Who make the polishing? In house or out house?

We have polishing workers in house. But for really higher polishing requirement, for examples, A1 stand polishing, we outsource, The supplier is about 3km away from our company.
How many types for Mold Manufacturing?
There are various types of molds for mold manufacturing. And the most common types are 2 plate mold, 3 plate mold/pin-point gate mold, hot runner manifold mold, thoroughly harden mold, and pre-hardened mold. 1)The two-platen mold, also known as the single parting surface mold, is the simplest type of injection mold. It divides the entire mold into two parts based on the parting surface: Moving mold and fixed mold. Part of the cavity is in the moving mold; part of the cavity is in the fixed mold. The main runner is in the fixed mold; the runner is located on the parting surface. After the mold is opened, the product and the runner remain in the moving mold, and the moving mold Some have an ejection system. Here is an image for your reference.
2)There are two parting surfaces that divide the mold into three parts, and a gate plate is added to the two-plate mold. This kind of mold uses a pointed gate, so it is called a pin-point gate mold.
3)With the help of a heating device, the plastic in the injection system will not solidify and will not be demolded with the product, so it is also called a non-runner mold.
4)The steel used in the inner mold part needs to be heat treated (such as quenching) after being purchased to meet the requirements of use, such an injection mold is called a hard mold.
5)The steel used in the inner mold part does not need to be heat-treated after purchasing, and it can meet the requirements of use. Such an injection mold is called a soft mold.
With the development of computer technology, CAD technology has become an important tool for product designers to conduct research and development. Among them, three-dimensional modeling technology has been widely used in product and mold design, program review, automated manufacturing, as well as management and maintenance. In the actual development and manufacturing process, the technical data received by designers may be three-dimensional models of various data types, but in many cases, they are physical models of products obtained from upstream manufacturers. Designers need to use a certain way to convert this physical information into CAD models, which is applied to reverse engineering technology.
There are several characteristics of mold manufacturing. Here are some of them for your information.
1.Mold manufacturing belongs to single-piece, multi-variety production. Each mold can only produce a single product, and the mold is generally not universal.
2.Customers require a short mold manufacturing cycle.
3.Complete set of mold manufacturing.
4.The precision of the mold is high, and the precision depends on the precision of the machine tool, processing technology, and measurement methods.
5.In the mold manufacturing process arrangement, the process is relatively concentrated to ensure the quality and progress of mold processing, simplify management, and reduce process turnaround time.
6.Mold working parts have complex shapes, high material hardness, heat treatment needs to be arranged in the mold manufacturing process.

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