SOME EXAMPLES OF PRODUCTS MADE WITH SOFT TOOLING
Below are shown some examples of plastic parts. These custom molded plastic parts are typical short run applications. Some were products required by established industries, and some are products introduced to the market by inventors who have experienced substantial success.
Shown here is a special purpose tool for opening and cleaning out termite poisoning stations.
The material is glass filled nylon; the 10 inch shaft contains a threaded metal insert in the end for the attachment of a metal digging auger intended to clean out drift sand and mud from a termite station. The hook on one side of the handle is an integrated lifter to pull out the bait container, and the small flat projection on the other side of the handle is a key to open the top of the station.
This tool replaces what were originally three tools, at a fraction of the cost.
HAND PROTECTOR
This hand protector is designed to attach to a 1 1/4" diameter stick (sword) used in medieval combat reenactments. These combats are done with full replica body armor, and, with a "no punches pulled" style of fighting, the protector must withstand heavy blows from an opponent's weapon. It is not unusual for 14 gage steel helmets to be dented in such melees, but the polypropylene-rubber graft polymer used withstands the hardest blows. The metallic coloring is achieved by the addition of aluminum flakes to the raw plastic material.
This is a case of a specialty market which would be prohibitively expensive to serve with conventional injection molding.
These colorful buttons for an ATM machine with raised letters and Braille, shown here mounted on the electronic switchbase, are molded in a family mold. The different colors are achieved by means of a rotary runner selector which allows only a given set of cavities to be run at one time. This cost saving technique allows the production of various parts from the same mold without the necessity of molding all of the parts at once, or even of the same material.
A variant of this technique is the family mold, in which a frame holds one or more sets of smaller "sub-molds" which can be switched or combined at will. DragonJewel has a selection of such frames, which can substantially reduce the cost of a variety of parts.
This ABS box for a dryer vent has an exterior decorative frame. Approximately 10" x 7", this molding weighs a total of 1 1/2 lbs. It provides the homeowner with a clean, safe way to attach the dryer vent of a clothes dryer to the exterior vent.
The metal insert provides UL required protection against heat, while providing a simple and safe connection to any dryer hose.
Short run molding allowed this innovative item to be introduced quickly at minimal cost, while providing a professional appearance which would have been unattainable with handcrafted or bent metal versions of the same concept.