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the Number of Cavities in a Mold


In plastic injection molding, the number of items that can be molded in one shot using one mold is called the number of cavities. The number of cavities can be from 1 to a reported maximum of 216. Since the number of items molded in one shot becomes large as the number of cavities becomes large, it is possible to reduce the cost of production per item. However, as the number of cavities becomes larger, there is a trend of […]

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Injection Molding Aluminum


Injection molding is a manufacturing process where a material is injected into a mold to create a desired shape. Typically, this process is used for plastics, but it is also possible to use it for metals like aluminum. Aluminum injection molding involves melting aluminum pellets and injecting them into a mold cavity under high pressure. The aluminum solidifies quickly in the mold, taking the shape of the cavity. Once the aluminum has cooled and hardened, the mold is opened, and […]

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Ejector Pin Design Principles


The ejection of a plastic product is the last step in the plastic injection molding process. The quality of the ejection determines the quality of the plastic product. When the mold opens, the plastic product must be retained on the mold half (usually the core) with the ejector mechanism that is used to release the plastic product. (1) In order to prevent the plastic product from deformation during ejection, the ejection force has to be distributed as evenly as possible, […]

MIM and AM: Solvent finishing of complex parts


As the pressure to produce smaller and more complex parts faster and more economically increases, manufacturing using MIM (metal injection molding) and AM (additive manufacturing) processes such as 3D printing is gaining widespread acceptance. Manufacturing options like MIM and AM have opened up design possibilities that are almost limitless, allowing designers to create parts that would otherwise be impossible to make using other manufacturing methods. For example, in the past, design compromises had to be made for parts that were […]

What is Sandblasting?


Sandblasting is a general term used to describe the act of propelling very fine bits of material at high-velocity to clean or etch a surface. Sand used to be the most commonly used material, but since the lung disease silicosis is caused by extended inhalation of the dust created by sand, other materials are now used in its place. Any small, relatively uniform particles will work, such as steel grit, copper slag, walnut shells, powdered abrasives, even bits of coconut […]

Comparing Metal Parts Manufacturing Methods


From machining to MIM, metal parts buyers have a wide range of options for addressing their part-production challenges. The key in choosing from among them is to remember that each technology brings something different to the table, and every part has unique requirements. Metal fabrication does not lack for depth as an industry. No fewer than 6 distinct — and commonly used — techniques exist for the manufacture of metal pieces and parts in 2019. Each can be considered the […]

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Coining


Coining is a closed die forging process, in which pressure is applied on the surface of the forging in order to obtain closer tolerances, smoother surfaces and eliminate draft. Closed die forging is a process in which forging is done by placing the work piece between two shaped dies. This process may be done in hot or cold working conditions, but is predominantly a cold work process. In coining, pressure is applied to a portion or the entire surface of […]

Secondary Operations for Powder Metallurgy Parts


A sintered powder metallurgy (PM) part can be finished or treated just like any other metal part to achieve desired characteristics-corrosion resistance, improve strength ans hardness, surface wear resistance, edge-sharpness relief, porosity sealing, and control of size and surface finish. Plating, coating, deburring, welding, furnace brazing, heat treating, and stem treating are among secondary operations that are used successfully in the process of fabricating finished PM parts. Unlikes parts made using other metal forming processes, powder metallurgy parts can be […]

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Common manufacturing processes for plastic and metal parts


One important tenet of Design for Manufacturing / Design for Assembly is the idea that the mechanical engineer and the industrial designer should choose the manufacturing processes that will be used to mass produce custom parts before finalizing the design for that part (and everything that it touches). Here are some common processes that are used to produce plastic and metal parts in consumer electronics and industrial automation applications. Some post-processes for plastic parts Sometimes plastic parts have to go […]

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Finishing Operations for Forgings


There are two categories of finishing operations: those that produce minor dimensional corrections, and surface treatment processes. Coining, sizing and straightening are commonly used to improve the dimensional accuracy of forgings. When tolerances closer than those that can be economically produced in the forging die are specified, coining and sizing operations are often employed. These processes cause plastic deformation of the forging, either by striking or squeezing a defined area. Coining may be performed either hot or cold, and can […]

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