molds, drill holes for cooling water channels.
Tapping/fitting (if required): Processing threaded holes or installing fittings (used to fix cooling water nozzles, mounting components, etc.).
Hand polishing: The fitter removes burrs, polishes the surface of the mold cavity (to achieve the desired smoothness or texture), and cleans it.
(Aluminum mold) Surface treatment (optional): such as sandblasting, anodizing (to increase wear resistance, corrosion resistance), etc.
D. 3D printing mold production:
Slice the 3D model of the mold.
Use metal 3D printers (such as SLM, DMLS) or high-performance engineering plastic/resin printers for printing.
Post processing: Remove support, polish, drill and extract air holes, etc.
4. Mold auxiliary structure production
Making a mold frame: usually welded from aluminum alloy profiles or processed from steel plates. The size needs to match the vacuum forming machine workbench and mold cavity. Process positioning holes, locking slots, etc.
Production/installation of exhaust system:
Process a vacuum chamber on the bottom plate of the mold frame or the back of the mold (ensuring sealing).
Drill through holes to connect the suction holes of the mold cavity to the vacuum chamber.
Install the vacuum quick connector.
Production/installation of cooling system (commonly used for aluminum molds):
Drill holes or embed copper pipes in the mold to form a cooling water channel circuit.
Install cooling water inlet and outlet connectors.
Making edge cutting die (optional): If the mold integrates punching function, a corresponding die needs to be made and installed on the mold frame.
5. Mold assembly and debugging
Installation cavity: Accurately install and fix the processed mold cavity (resin block, aluminum block, etc.) inside the mold frame. Ensure accurate positioning and secure fastening.
Connecting pipeline: Connect the vacuum pipeline to the vacuum joint; If equipped with cooling, connect the cooling water pipeline.
Check sealing: Focus on checking the sealing of the vacuum chamber and vacuum pipelines to ensure no leakage.
Installation to vacuum forming machine: Install the assembled set of molds (upper mold frame+lower mold frame) onto the vacuum forming machine, adjust the position and alignment.
6. Trial molding and mold repair
First trial mold: Use actual production materials (or similar materials) for trial production.
Check the product:
Is the molding complete? Are the deep cavities, sharp corners, and details clear?
Is the wall thickness distribution uniform? Are there any areas that are too thin or too thick?
Is the demolding process smooth? Are there any deformations, cracks, or scratches?
Is the flying edge even? Does it meet the trimming requirements?
Is the dimensional accuracy up to standard?
Does the surface quality (gloss, texture) meet the requirements?
Analyze the problem:
Poor molding: usually related to insufficient air extraction (hole blockage, air leakage, improper hole position/density), insufficient heating, insufficient pressure, and insufficient cooling.
Demoulding issue: Check if the demoulding slope is sufficient, if the surface is smooth, and if it is necessary to adjust the ejection mechanism or spray demoulding agent.
Uneven wall thickness: adjust the heating method (zone heating), sheet pre stretching, vacuum degree, forming speed and other process parameters; In extreme cases, the mold needs to be modified (such as adding auxiliary plungers).
Mold repair:
Clean the blocked exhaust holes.
Repair the leakage point.
Increase, expand, or adjust the position/density of the exhaust holes.
Polish and polish to improve demolding.
Minor modifications to the profile (such as reinforcing rib height and fillet size).
Adjust the cooling water circuit (if it affects the uniformity of cooling).
Sometimes it is necessary to modify process parameters (temperature, vacuum degree, time, etc.) to adapt the mold.
Repeated mold testing and repair: until a qualified and stable product is produced. This process may cycle multiple times.
7. Final delivery
Confirm that the mold meets all requirements and production is stable.
Complete final cleaning and rust prevention treatment (especially for aluminum molds).
Deliver molds and related documents (drawings, operating precautions, etc.) to customers or production departments.
Key considerations:
Cost: GypsumCycle: Gypsum/resin molds are faster, CNC aluminum molds are slower, and the speed of 3D printing metal molds depends on complexity and equipment.
Durability/lifespan: Aluminum mold>Electric wood mold>Resin mold>Gypsum mold. Aluminum molds must be selected for large-scale production.