Aluminium moulds can be used to manufacture large quantities of plastic injection moulded parts. Moulds must be designed and manufactured in the same way as steel moulds and must be processed in the same way as steel moulds.

There may be some restrictions on using aluminium moulds in certain situations, but the potential for each application, whether short-term or production process, including applications using high-temperature materials and glass tempered resins. It can be considered feasible.

Aluminium Casting Mould has always been considered a “soft” tool, and discussions about their use in mass production have been considered taboo. The idea limits the ability of moulders and their customers to take advantage of many of the benefits of aluminium to provide moulded plastic products with faster response times, faster cycles, lower costs, and often higher quality.

The study shows that aluminum moulds are 50% cheaper, deliver in half the time, and produce higher quality products in cycle time than similarly designed and manufactured tool steel molds. It decreased between 25 and 40 percent. This data was collected for different moulds and different product designs using different plastic moulding compounds.

This shattered the old notion that aluminium moulds are not strong enough to withstand the production process rigors for large quantities of long-term injection moulded products.

Since its announcement, many other companies have admitted that they have experienced the time and money savings of using aluminium moulds for production purposes. For some time, plastic magazines were full of direct explanations of such success.

It became clear that many moulders used aluminium moulds for production purposes for years, but others, especially customers, due to the stigma of “soft tools” placed on the moulds.

Keep in mind that aluminium is not the best option for all applications. Those familiar with the strengths, weaknesses, costs, contacts, and basics associated with using aluminium moulds should investigate their respective circumstances. However, with that said, there are very few cases where aluminium moulds do not benefit.

It should also be noted that only certain aluminium grades are properly machined and can withstand the pressure associated with injection moulding. In terms of cost, aluminium usually costs three times the tool steel weight, but because it weighs one-third the weight of tool steel, both have the same initial cost.

Wear and hardening problems

Does aluminium wear faster than steel and need to harden? Aluminium wears better if it doesn’t cure. However, many users use some form of curing by anodizing or other surface treatments.

However, you need to be careful about anodizing. It will come off from a corner of 90 degrees or less. This can be repaired by removing the anodized finish and re-anodizing, but this is not a cost-effective method.

There are other ways to cure the surface of aluminium. One of the most popular methods is a nickel-based, Teflon-based method offered under a variety of trade names. It applies to the surface and can be removed and reapplied if necessary. Detailed information is available from mold makers who specialize in aluminium moulds.

Machining and polishing

Experience has shown that the best grade of aluminium used is the “aircraft” grade. It is known as Grade T-6 (7075) and does not use a gum cutter or shredder. It is weld able and can be machined using EDM. Aluminium is machined about four times faster than moulded steel and two to three times faster than pre-cured P-20s. The immediate smoothing ability of the aluminium microstructure allows the surface to be polished in a standard procedure with fewer steps.

Due to its extremely light weight, aluminium can be processed with smaller equipment and faster feed. The larger the surface contour, the greater the savings available in aluminium due to the high speed and high feed available.

Shortening cycle time

Aluminium dissipates heat up to 7 times faster than steel, reducing moulding cycles by 20-50%. This heat dissipation is very uniform and less prone to warping due to different shrinkage, resulting in parts that maintain excellent dimensional stability. Even the heat distribution also reduces the physical residual stresses that would normally be released at some point in the life of the product and cause failure. And finally, less scrap production due to warpage, cracks, short takes and distortion.

Mental set

Countering the benefits of using aluminium moulds may be the idea of ​​some staff. People tend to think of aluminium moulds as “cheap” and “poor” imitations of steel moulds. Therefore, they have less time to wait and tend to be unable to handle aluminium moulds well. This way of thinking can and should be changed. This can be done by planting in the staff that the Aluminium Casting Mould.

can last as long as the steel mould if the aluminium mould is treated the same as the steel mould. That is, there is no screwdriver to remove the part, the slime does not close and is handled properly. One company paints all aluminium moulds with golden paint to convey that these moulds are as valuable as steel moulds. Staffs treat those moulds with children’s gloves and gentle love and care.

Successful switching to aluminium moulds may require a change of mindset and proper staff guidance and training. Many mould makers, especially veterans, are reluctant to test aluminium for anything other than prototype moulds. But when used in production tools, you quickly realize its value and benefits, and even find that aluminium offers far more artistic and creative opportunities than standard steel moulds.

Many companies recognize that if a steel mould is damaged, the operator must have done something wrong, but if the aluminium mould fails, it’s an aluminium failure. This is a typical idea for aluminium moulds. However, if the aluminium mould is designed and manufactured in the same way as the steel mould, it will work in a production environment.

Many companies are enjoying the benefits of aluminium moulds, especially in the current economic situation where all penny of profit is more important than ever. Even mould suppliers have seen trends and most offer aluminium mould base and component options in their catalogs, in addition to the standard steel options they have always offered.

About the company:

Aluminium moulds can significantly save initial mould costs, reduce lead time to make moulds, reduce cycle time to execute moulds, and reduce parts’ waste.

Novel Mould is the best company in moulding the material with aluminium. It is known for its good work in the fields of aluminium moulding.