Design Molds That Can Be Modified And Reused
Molds are expensive to make. They use high-quality materials that are time-consuming to machine into the right shape. One-way designers can reduce costs is by reusing prototype molds as they develop their projects. It is possible to remove metal from a mold, but it is almost impossible to build a mold back up. This means that the prototype can be altered, as long as these alterations only involve taking metal away from the mold or making the prototype bigger in some way.
A designer can use this knowledge to their advantage by planning the simplest, smallest prototypes first, and then changing it as they continue to develop the project to be bigger or more complex. This works especially well on projects with pieces that might be made longer or changed to be larger as the project progresses.
A designer can plan to make molds this way in order to cut costs as they develop their design and test it out through the creation of new prototypes. An excellent designer can help a client to save money by planning to create prototypes that allow the mold to be reused.
Other Tips For Reducing Costs When Planning Injection Molding Projects
Design is vital in reducing the costs of an injection molding project, but design alone is not the only factor to think about when creating a well-planned and cost-effective injection molded project. The following tips focus on other factors that influence the cost of a project and provide ideas on what can be changed or altered for the sake of producing a streamlined project with a lower cost of production.
Our Mold Cost Calculator Designed By Excel Spreadsheet
Calculating the mold price is like going through a simplified mold design process, it usually takes half to one hour to do the calculation for a mold.
We have designed an excel spreadsheet with a set of excel formulas to help to estimate the mold price. With the help of this spreadsheet, it will only take 1 or 2 minutes. However, the result will not be as accurate as the human calculation, but it can usually be within +/-15% of accuracy.
Our cost estimation report will look like below:
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Know How To Avoid Difficult Mold Designs
Undercuts are portions of a design that prevent the product from pulling easily and cleanly out of the mold. When designing an item, its most efficient to eliminate undercuts from the design. Undercuts make it difficult for the item to be ejected from the mold, which increases production time.
Additionally, creating a mold that includes undercuts costs more as it is difficult to make. Where possible, a designer should eliminate undercuts and instead use other design techniques to create an item with the same functionality. This will cut down on costs by ensuring the mold is less expensive and will additionally lower the production time.
Creating molds of core cavities can also help lower production costs. For example, when designing molds for a structure like a box, a design for assembly service can, rather than machining a deep cavity into the metal to create the sides of the box, create a mold for the inside of the box and form a bigger part that goes around this to form the sides. Strategically planning molds and using molds for core cavities where possible cuts down the costs of creating the molds, which is a major expense in injection molding.
Types Of Plastic And Effect On Plastic Mold Cost
When it comes to the cost of injection molded plastic parts, the type of plastic resins also comes into play. Depending on what the part is designed to do, you may choose a plastic material that is less costly or very inexpensive. Some of the plastics characteristics that can affect cost are:
- High Impact
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Reducing Injection Molding Costs
The cost of the mold is largely defined by the complexity and the amount of time it takes to produce it. We advise adhering to design for manufacturing principles to drive down part costs with injection molding.
The cost of producing the mold can be reduced by applying the following design guidelines:
Evaluate the CAD model to determine its feasibility before undertaking an injection molding project. Eliminate potential bottlenecks such as steep angles, undercuts, and other complex geometries.
Evaluate the models design to eliminate unnecessary features. This reduces the molds size and the material used to develop the model.
Apply a core cavity approach that simplifies the design of Side B of a mold. The core cavity approach involves sinking the wall cavities into the mold base, thereby reducing the need to mold steep draft angles while improving surface finish.
Embrace the use of self-mating parts to reduce the need to create multiple molds when one universal mold can be used to achieve similar results.
How Much Does A Plastic Prototype Cost
One of the difficult parts of sourcing prototypes is knowing how much you should be spending during this stage of the project. While your budget may be focused on the end goal , the prototyping stage is meant to set you up for successful production.
A good prototype will help you catch & fix any design flaws, figure out the best material to produce your parts with and ultimately save your project money in the long term. It will also allow you to test your product with confidence, knowing that any issues are a design flaw that needs to be tweaked rather than a fault of a poorly made prototype.
So how much does a proper plastic injection molded prototype cost? At the Engineering Resource Center, a simple plastic injection molded prototype starts at around $3,000 but the exact number will depend on part size, complexity, material, quantity, and number of cavities in the mold.
Our quotes include:
- Sample fee
- Part price
There are a few things to know about our tooling before comparing our prices to other similar companies. Some of these might make the initial cost a bit higher, but in the long term it really does even out.
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How Do You Inject Plastic Mold At Home
Home Plastic Injection Molding With an Epoxy Mold.
Quick Answer: How Long Does It Take To Injection Mould
Typically the cycle time for an injection molded part can be anywhere from a few seconds to a few minutes.
Many factors determine this such as the size of the part, the material being molded, the mold design as well as the part design.
Set up time for a mold can range anywhere from a few minutes to a few hours.
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Making Injection Molding Cost
Injection molding is typically described as a cost-effective manufacturing process when ordering large quantities of parts.
The reason for this is simple: with injection molding, the initial tooling costs are very high, while the actual plastic molding costs are very low, which means the effective cost-per-unit becomes lower when more units are required.
For example, imagine that a stainless steel mold for a toy car costs $5,000, and each plastic toy car made with the mold costs $0.50. In this scenario, ordering 1x unit of the toy car would cost $5,000.50, ordering 2x units would cost $5,001, and ordering 1,000x units would cost $5,500.
In all of the scenarios, the mold accounts for the bulk of the cost, so the total cost does not vary greatly.
However, in these three scenarios, the effective cost-per-unit does vary greatly:
|Scenario in which mold costs $5,000 and each molded part costs $0.50|
As you can see, there is a dramatic reduction in cost-per-unit when the unit quantity increases, since the extra units amortize the high cost of the mold.
Ordering more units of the toy car clearly represents better value for money.
And while there is no simple formula for determining the point at which injection molding becomes more cost-effective than 3D printing, there are certain factors we can take into account that will help us make the right decision.
The True Cost Of A Plastic Injection Mold
Asking for the cost of a plastic injection mold isnt an easy question to answer, but its the most important one when starting the manufacturing process. Its a lot like asking How much is a house? Are you looking for a starter home with 1 bedroom and 1 bathroom for you and your cat or are you looking for a 4 bedroom, 3 bathroom, split level house on 2 acres with a detached 3 car garage, in ground swimming pool and room to roam for a growing family.
Just like there are homes for different stages in your life, there are different molds for parts and the costs are just as different. Depending on what you are molding and how many parts you are planning to make will decrease or increase the cost of the mold. But there is good news, the mold will be the biggest cost out of the process, with very low per product costs for many years to come!
If your part is semi to very complex then the mold itself is going to be expensive. You wouldnt expect a Rolex watch to be made with anything less than pristine tools and parts and by a trained Watch Engineer now would you? If you want to put out a high quality product with a great reputation why would you opt to save a little bit of money for a cheap mold which will only harm your product and your future profits?
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Plastic Injection Molding 101
One of the most common questions for those looking to source a plastic injection molder is How much will a plastic injection mold cost? It’s one of the most important questions, since the actual mold represents the most significant expense in upfront production costs. That being said, many factors go into determining the full cost. With any custom injection molding project, your injection molder should be able to give you the final price tag. In this article, we will review the variables that can impact the cost so that you can be better informed when making a mold purchasing decision.
Mold Length And Width
The next thing to do is determine a rough estimate of the mold size. For the sake of example, lets say the part is 2 in.2 and the customer wants or needs four cavities in order to meet either his sales volume or his target part price. If you assume the spacing between the edges of the cavities is 2 in. and there are 3 in. from the outer edges of the cavities to the outer edges of the mold, that works out to a mold size of roughly 12 × 12 in. Now find the smallest machine in which this mold will fit vertically between the tiebars , but not extend beyond the outer edges of the platen.
Stack molds can require very large mold-opening strokes, which add to cycle time and affect the choice of appropriate molding press.
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The Cost Of The Material Makes A Difference
Pellets for injection molding are purchased in bulk, so the cost of material is comparatively small when considering other costs associated with injection molding. Be sure to add in the cost of the runner system when you assess the weight of the material as well. Note that since the cost is already on the low side, there may be little room to make reductions in the cost of the material.
Injection Molding Cost Calculators
Online injection molding cost estimators or quotes from injection molding service providers can provide benchmarks and help you estimate the cost of injection molding specific parts.
Injection molding cost estimator options to aid the calculation process include:
A molding cost comparison table also serves a similar purpose. Injection molding service providers use cost comparison tables to provide prospective customers with a rough estimate of the process.
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Major Variables That Affect The Mold Price
How To Correctly Calculate The Cost Of Injection Molding
The best way to figure out how much you can save withinjection molding services over other manufacturing methods is to compute the cost per part. Although there are certain factors that can drive the cost of injection molding up or down, if you begin with the right formula to calculate the cost per part, you may be able to make adjustments that will lower that figure.
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Why Are Injection Molds So Expensive
If you have ever looked into injection molding for your plastic parts, your first question was likely why are injection molds so expensive? An injection mold is easily the most expensive part of the project, and can dramatically increase costs for small part runs. The main factors that influence the cost of an injection mold are the size and intricacy of the part, the material used, and the number of parts being produced.
Plan The Surface Texture Of A Project From Day One
An injection molded project will take on the texture of the mold. That means that if a specific texture is required on the project, it must be added to the mold. It can be added by hand or by chemical etching. Adding a texture means extra cost, but this can be worth it for the aesthetic appeal.
However, the texture of the finished project plays a part in the draft of the mold, so the texture desired in the final outcome must be planned for from the beginning stages of the project. Failing to plan for this means that the item may not come out of the mold well.
Any other embellishments, symbols, or text desired on the project should also be planned for from the beginning and should be at least 1.5mm high. Additionally, there should be a 0.5mm width between any text or features.
When planning to use text, a designer should use a simple sans-serif font with letters that are not significantly depressed into or embossed onto the item. Following these rules when designing additional features for the surface of an injection-molded item will ensure cost-efficiency when mass-manufacturing an item.
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Number Of Part Cavities
The number of part cavities within the mold will directly affect the price of the mold. Parts that only require a low quantity of parts per customer order will be constructed as a 1 cavity mold to produce only 1 part per machine cycle, and parts with a high quantity of parts per customer order might be constructed as a 2, 4 or 8 cavity mold producing several parts per machine cycle.
Multi-cavity molds will certainly cost more than single cavity molds, however, keep in mind that part pricing will have an inverse relationship to mold cost when considering mold cavitation and a projects total overall cost.
Understanding The Cost Of Injection Molds
The cost of injection molds varies based on the part and the application. Molds could be a few thousand dollars or hundreds of thousands. The plastic part a mold produces may be a commodity, but the mold is far from it. They are custom-built for the specific application. Below you will find major contributing factors in the cost of a mold.
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If Youre Still Determining The Cost Of Plastic Injection Molds Baytech Can Help
For over 70 years, have been supplying customers with superior molded parts and components. They have the experience to help you in determining the costs of plastic injection molds. They can guide you through the every step of the process, from tooling to your finished product. for more information on how their seven decades of experience can help your project flourish.