Technology Roundup: Mold Maintenance, Repair and Surface Treatment Essentials

MRST

Micro Welder Simplifies Mold and Die Repair

Rib Puller Tool Reduces Injection Mold Downtime

Photo Credit: DW Sales

A Rib Puller, which is offered by Mold Shop Supplies, is a special tool for pulling out the stuck, broken off or jammed plastic in the deep slot or rib that is in many injection molds. Once plastic is stuck and breaks off in a rib, DW Sales says, it is imperative to remove it to avoid long periods of downtime.

Historically, the mold repair or toolroom repair guy either had to remove the stuck plastic in the press or shut the press down, remove the mold and move it to the tool repair room. Short of scraping out the plastic, pieces of hack saw blades or flattened screws were typically used, which took time to make and could easily scratch up the tool surface.

The Rib Puller comes in three sizes, RP112 at 1 ½", RP234 at 2 ¾" and RP4 at 4" for deeper ribs. 

Digital Tool Services Solve, Troubleshoot Coating, Finishing Issues for Molds

Photo Credit: Bales Metal Surface Solutions

Bales Metal Surface Solutions, delivering metal surface coatings and surface finishes that protect the life of molds, dies, tooling and components, has launched three digital tools designed to help manufacturers learn about and solve an array of finishing issues.

Bales developed the new online offerings amid shifting consumer preferences during the coronavirus pandemic. The free digital tools extend Bales’ finishing expertise and quality customer service online. They are said to simplify the finishing process, giving manufacturers access to valuable information about coatings and finishes anytime, anywhere from a mobile device.

On-Site Mold Repair Flexibility Enhanced With Fiber Laser Welding

Photo Credit: LaserStar Technologies Corp.

Today’s mold repair micro-welding laser industry is characterized by rapidly changing, ever-evolving customer demands and intense competition. With its fundamentals in innovative ideas, successful designs and a commitment to quality and performance, LaserStar Technologies Corp. calls attention to the FiberStar 8900 Series CNC welding workstations.

The state-of-the-art laser resonator technology provides high peak power, optimal performance and throughput, higher uptime, enhanced electrical efficiency and a space-saving air-cooled design. Solid-state diodes are reported to provide instantaneous power with no “warm-up time” required.

Mold Repair, Surface Treatment Service Provider

Photo Credit: High-Tech Laser & Polishing

High-Tech Laser & Polishing is a service provider that supports mold builders and molders with multiple services that include mold polishing, laser engraving/texturing and laser welding.

The company engraves on tool steels, aluminum, copper and graphite for electrodes. Logos, cavity ID, tool identification or text can be accomplished on a contoured surface, a sidewall or down in a deep pocket. High Tech Laser also has laser cutting capability for a 5' x 10' sheet of material. Laser cutting can range in material thickness from 0.003" – 0.500" thick.

Universal Lubricant Designed for Injection Molds, Extreme Manufacturing Environments

Photo Credit: PCS Company

PCS Company is now distributing Min-Lube, an advanced universal lubrication product designed for extreme high-temperature, high-wear mold and die applications as well as food and pharmaceutical manufacturing environments.  

Min-Lube is made in the U.S. with a premium-quality, environmentally suitable ISO 100-rated oil base that is combined with a proprietary calcium sulfonate complex and a carefully selected additive package. The lubrication product offers thermal, oxidative and mechanical stability. Plus, Micronox is added to provide antimicrobial protection to prevent degradation of the product.

Injection Mold Buildup Removal Solution

Photo Credit: Slide Products

Slide Products’ Nexgen Mold Cleaner is formulated to offer more cleaning strength than other “natural” mold cleaners, while quickly but efficiently breaking down resin deposits. The mold cleaner does not use chlorinated solvents and comes in 1-, 5- and 55-gallon cylinders. Flush cleaning the mold with X-empt Injection Mold Cleaner, a fast-evaporating, single-purpose mold cleaner formulation, or Mold Cleaner 4 — good for removal of silicones, grease, oil and wax buildup — after scrubbing off any buildup will reportedly produce a flash off for a “no touch” finish.

Dry Ice Blasting for Faster, More Efficient Mold Cleaning

Cold Jet highlights its PCS60 and i³MC2 dry ice blasting machines as best suited for the quick, safe and efficient way to clean any type of molds and a variety of mold finishes up to and including A1 surfaces and textured surfaces, all while improving overall equipment effectiveness (OEE) operational efficiencies. This includes injection, blow, PET preform, LSR and LIM, thermoform, technical, HDPE, medical device, extrusion dies and metal injection molds, just to name a few.

Dry ice blasting is a non-abrasive process, does not produce secondary waste and enables users to clean their molds in the press at operating temperatures. Cold Jet says this leads to improved productivity, higher quality parts and reduced costs. 

LMD Processing Extends Time Needed Between Tool and Die Repairs

Photo Credit: Trumpf Inc.

With the compact and high-precision five-axis TruLaser Cell 3000 from Trumpf Inc., users can repair and add features onto existing molds, tools and dies. The TruLaser Cell 3000 is a laser metal deposition (LMD) system that uses powder metal and a laser to deposit material, bringing more control and lower heat input into mold and die repair, particularly when compared with the more manual repair process that is traditionally performed, Trumpf says. The five-axis cell’s flexibility enables operators to choose between six different processing nozzles, unlocking customized deposition rates, surface roughness and high hardness tool steels like H11 or H13. The laser welding technology from Trumpf may also help extend the number of cycles between die repairs compared to traditional manual repair methods.

Welding Repair Services for Additive Manufacturered Molds

Photo Credit: Precision Laser Technology

Precision Laser Technology and Mantle conducted a study to repair 3D-printed bars built from Mantle’s H-13 metal paste utilizing laser applications and conventional machining methods. The printed bars rated a Rockwell C hardness of 42 and were precision ground to within 0.0005" to assess surface quality and machining performance. There was zero evidence of pitting and no signs of wheel loading or heat generation during grinding. The finished bars were then damaged along the edge to simulate a worn out parting line or mold crash from a misaligned insert.

Mold Cleaning System Removes Buildup, Prevents Rust for PVC Processors

Acid vapors caused by processing PVC causes flash rusting on molds and components. If not treated properly, the issue can compound, becoming increasingly difficult to eliminate. Eco-Pro 360 from iD Additives is able to quickly remove, and help prevent flash rusting.

The water-based plastic mold cleaner is a non-aerosol, non-flammable and ready-to-use solution. According to iD Additives, it safely removes rust, mineral and limescale buildup, providing a protective nanocoating for rust prevention. It also works on all metal surfaces (without etching) and can be reused with proper filtration.

Descaling Pumps Keeps Mold Heating, Cooling Circuits Clear of Debris

Photo Credit: Mouldpro ApS, Globeius Inc.

The compact and portable Descaling Pump from Denmark-based Mouldpro ApS and distributed in North America by Globeius Inc. keeps heating and cooling circuits on molds and molding machines clear of rust and limescale deposits. 

Blocked or severely corroded circuits can have a significant impact on machine efficiency. Even a thin layer of scale or corrosion can act as an insulator that slows production. Mouldpro’s Descaling Pump, when used regularly with the company’s specially formulated descaling solution, is said to ensure clear circuits.

Cloud-Based Asset Management System Attains Next-Level Mold Monitoring

Photo Credit: Progressive Components

Progressive Components has provided the industry with new mold monitoring advancements for nearly 30 years and continues with its introduction of ProFile v4, an advanced cloud-based asset management system.

According to Progressive, ProFile can be used as a simplified tracking system to organize, maintain and track global tools and equipment or interface with Progressive’s CVe Monitor for complete real-time monitoring, maximizing the monitoring, maintenance and production capabilities of OEMs, molders and mold builders.

Spotting Press Facilitates Safe, Productive Adjustment, Inspection and Repair of Molds

Photo Credit: Millutensil srl

Millutensil is a dynamic family-run company with almost 70 years of experience in the production of mold and die spotting presses, die splitters and machinery for sheet metal processing. The Blue Line production line, specifically, has enabled Millutensil to establish itself in the automotive industry worldwide, thanks to its advanced technology and product quality.

This line includes a wide range of mold spotting presses, i.e., high-precision machinery that facilitates the adjustment, inspection and repair of molds. Currently, molds are becoming increasingly complex, so it is necessary to use the right technology to replace obsolete, inaccurate and unsafe methods, such as overhead cranes and forklifts.