Do Complex Rapid Injection Molding Designs Need to Be Simple?

Rapid injection molding requires that your part design should be as simple as possible, right? This is another false assumption as we support complex part designs that require undercuts, through holes, and other features. Complex designs can be efficiently handled with the right expertise and equipment, allowing for more innovative and functional parts. 

Undercuts, such as those shown, can complicate and, in some cases, prevent part ejection, so eliminate them if possible.

How Do External Undercuts Enhance the Injection Molding Process? 

External undercuts are the easiest and most cost-effective as we accommodate through pin-actuated side-actions. These side-actions move in tandem with the mold when it is opened and closed while the cam rides along an angled pin. When opened, the cam is fully retracted so the part can be easily ejected without mold damage and closes again till the cam is in position to create the next part. This method ensures that complex parts can be produced quickly and accurately, maintaining high quality and reducing production time. 

What are the Advantages of Using Pin-Actuated Side-Actions? 

Pin-actuated side-actions are advantageous because they allow for the creation of intricate external features without compromising the integrity of the part. They provide a reliable mechanism to handle complex geometries, ensuring parts are molded to exact specifications. This method also minimizes the need for additional post-processing, saving both time and cost. 

What if Parts Are Not Adaptable for Side-Actions? 

In cases that are not adaptable for side-actions, we can use manually removed inserts. These are mold components that are greater than a half-inch cube and are loaded by an operator into the press before it closes. After the part has been molded, the part is ejected along with the insert. The operator then takes the part and manually removes the insert and places it back into the mold for the next part. This process, although more labor-intensive, allows for the creation of parts with complex internal features that cannot be achieved through side-actions alone. 

To mold a test tube with just a core and cavity, extra draft and wall thickness are needed. By laying the test tube down and using a side action for the core, you can eject it on its side and reduce the required draft.

What are the Benefits of Manually Removed Inserts? 

Manually removed inserts offer flexibility in mold design, enabling the production of parts with internal features that are otherwise difficult to mold. They are particularly useful for low to medium production runs where the added labor does not significantly impact overall costs. Additionally, manually removed inserts allow for quick adjustments and iterations in part design, facilitating rapid prototyping and testing. 

How Does LaFlesche Ensure High-Quality Results? 

LaFlesche's commitment to precision engineering and advanced manufacturing techniques ensures that even the most complex part designs are produced to the highest standards. Our use of state-of-the-art CNC milling machines and rigorous design for manufacturability (DFM) analysis allows us to optimize every aspect of the molding process. This ensures that parts are not only produced efficiently but also meet stringent quality requirements, making LaFlesche a trusted partner in the injection molding industry. 

What is the Conclusion? 

Rapid injection molding at LaFlesche is not limited to simple part designs; we excel in accommodating complex designs that include undercuts, through holes, and other intricate features. Our expertise extends to external undercuts, which are efficiently managed through pin-actuated side-actions, ensuring smooth part ejection without mold damage. For designs that do not suit side-actions, we offer manually removed inserts, enabling operators to swiftly remove inserts after molding, facilitating a seamless production process. At LaFlesche, we prioritize versatility and precision in every aspect of our rapid injection molding services, guaranteeing high-quality results for even the most challenging part designs.