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 SHOWN HERE IS A VERY COMPLEX MOLD HAVING THREE HYDRAULIC CORE PULLS AND INTERNAL THREADS.

    THIS MOLD MAKES A SPECIAL DEWATERING BOX FOR TENNIS COURTS. ALTHOUGH THIS IS A SPECIALTY PART WITH A RELATIVELY LOW USAGE, ON THE ORDER OF A THOUSAND PER YEAR, THE MOLD COST WAS REGAINED WITHIN THE FIRST RUN OF 1000 PARTS WHEN COMPARED TO THE ORIGINAL PRICE OF PRODUCING THE PART BY GLUING STANDARD PVC PLUMBING FITTINGS TOGETHER. ADDITIONALLY, THE ABS PLASTIC IS FAR TOUGHER THAN THE PVC, WHICH SUFFERED BREAKAGE IN HANDLING.

    THE MOLD IS SHOWN RUNNING ON OUR 250 TON, 20 OZ. CINCINNATI MOLDING MACHINE.

 

 

 

 

   

 

   SHOWN TO THE RIGHT IS OUR 100 TON 8 OZ. VAN DORN MOLDING MACHINE WITH A 5 CAVITY MOLD TO PRODUCE 5 DIFFERENT PLUMBING FITTINGS; AN END CAP, TEE, ADAPTER, COVER AND REDUCER. NONE OF THESE PARTS DUPLICATE STANDARD PLUMBING FITTINGS, AND THE ORIGINAL PRICE OF CNC MACHINING THE PARTS FROM STOCK MATERIAL WAS ALMOST 100 TIMES THE PRICE OF THE MOLDED PARTS.

    NOTE HOW FEW WATER LINES ARE ON THE PART FOR COOLING. ONE OF THE ADVANTAGES OF ALUMINUM TOOLING IS THAT HEAT TRANSFER IS 8 TIMES AS HIGH AS STEEL, WHICH ALLOWS MORE EFFICIENT COOLING WITH FEWER LINES AND MORE UNIFORM TEMPERATURES. IN TURN, THIS MEANS PARTS WITH LESS MOLDED-IN STRESS.

 

 

 

     OUR SMALLER MACHINES, SUCH AS THIS 55 TON VAN DORN ARE IDEAL FOR FAST RUNNING SINGLE CAVITY MOLDS.

       PROPERLY SIZING THE MACHINE TO THE MOLD IS IMPORTANT IN OPTIMIZING PRODUCTION AND MINIMIZING COST. OUR MACHINES, FROM 14 OUNCE, 200 TON ON DOWN TO 2/3 OUNCE 9 TON HAVE APPROPRIATELY SIZED MUD MODULAR, FAST INTERCHANGE MOLD BASES, WHICH CAN OFTEN REDUCE THE TOOLING COST AND MINIMIZE SETUP COSTS ON SHORT RUNS.

    THIS PARTICULAR MACHINE HAS BEEN MODIFIED FROM ITS ORIGINAL CONSTRUCTION TO ALLOW VERY CLOSE CONTROL OF THE INJECTION CYCLE, TIMES, PRESSURE AND SPEED. IT IS REGULARLY USED TO PRODUCE CASH REGISTER COIN CUPS AND HOLD THE WEIGHT TOLERANCE TO THE REQUIRED ACCURACY OF 1/2 GRAM.

 

 

 

 

     WE USE FORTAL(tm) ALUMINUM FOR OUR SHORT RUN MOLDS. THIS 7075 ALUMINUM ALLOY, WITH ITS SPECIAL HEAT TREATMENT AND ROLLING PROCESS IS ADMIRABLY SUITED TO MAKE SHORT RUN, HIGHLY ACCURATE MOLDS. MOST MOLDS MADE FROM FORTAL CAN EASILY EXCEED 100,000 OPERATIONS.

    HARD STEEL INSERTS ARE SOMETIMES USED WHERE VERY HIGH WEAR POINTS, SUCH AS SLIDING SHUTOFFS OR SUBMARINE GATES ARE NEEDED, TO PREVENT LIKE-METAL GALLING WEAR.

    OUR TOOLING SHOP REGULARLY PRODUCES MOLDS FOR AVIATION, MEDICAL, CONSUMER, ELECTRONICS, RECREATION, GOVERNMENT AND LAW ENFORCEMENT APPLICATIONS. WE CAN QUOTE YOUR NEEDS FROM PRINTS, SKETCHES, CAD DRAWINGS OR EVEN VERBAL CONSULTATIONS.

    IN THE ILLUSTRATION TO THE RIGHT, A MOLD FOR PROTECTIVE ARMOR IS BEING MACHINED. THE DESIGN CAME TO US AS A HAND-MADE PROTOTYPE.