By having the capabilities entirely in-house, we are able to do the molding internally and also the correction of the tool, which reduces the time for correction loops significantly.
The fewer adjustments required the better, as the process is then faster. That is where experience is vital, especially for new parts, where you run the tool on the machine for the first time. It is key to use the correct settings and to analyze the results in order to make the necessary changes and to achieve the desired end results. For this we use the first-of-tool (FOT) parts process, making the tool slightly smaller in the first instance and then recorrecting the mold by removing material to ensure the optimal size.
In addition, we are able to take full advantage of our in-house simulation capabilities, using mold flow technology to simulate the material’s behavior during the injection molding process to help achieve the most accurate first design. It is not possible to make a tool to exact tolerances without a first trial, but we can get close through these simulations in order to further reduce correction loops.