Tool Design

The basis for providing a quality product is the design. Our Design Department employs 20 experienced Design Engineers using the most advanced modeling software. This not only cuts the lead time for supplying production parts, but the potential for human error is also greatly decreased. Acceptable file formats include UGII, Cathia, Parasolids, and Iges files.

Using parametric fundamentals of design, the team creates tool design models that have complete associativity throughout all of the different components of an assembly. This means that both major and minor changes to a product can be made and reviewed with the customer through all stages of design and build of a precision injection mold. Design changes are communicated electronically in real time to the machine programmers who are shaping the steel.

ARC Tooling’s Engineers routinely recommend solutions to customers that can increase product performance, product lifecycle, reliability, and profitability both for ARC Tooling and for the customer.

Mold Types

Single cavity molds offer the lowest tooling costs and highest precision at the penalty of higher unit costs. Multi-cavity molds are utilized to increase capacity and lower unit costs.Family molds, multi-cavity molds with different items together, offer both the lowest mold cost and low unit cost. However, they present other problems of matching the process conditions for each part.

Moldflow Analysis

All tools produced by ARC Tooling will go through a thorough moldflow simulation.

ARC Tooling’s design engineers work closely with a selected specialist firm using mold simulation software to optimize the product design and manufacturing process and perfect it, before the first piece of steel is cut. This process reduces the time needed to condition the mold and speeds the product to market.

Design & Engineering Experience

  • Stack Tools
  • 2K Tools
  • Expandable and Interchangeable Tooling
  • Multiple Slide Action Molds
  • Stripper and Floating Cavity Plate Molds
  • Unscrewing Molds

Materials

The materials used to construct injection molds range from aluminum to hardened steel:

Pre-hardened Tool Steel (for moderate production, more complex molds)

Pre hardened tool steel molds are strong and durable, yet still soft enough to be worked by conventional machining processes such as milling and turning. Pre hardened tool steel molds are typically intended to produce from twenty thousand to five hundred thousand parts, and can have a wide array of features such as slides and more intricate shapes.

Examples are DIN 2311, and DIN 2738H

Hardened Tool Steel (for high production, long life molds)

Hardened steel molds are intended to produce one million or more parts. Their hardness enables them to resist wear from their own operation and the abrasion of the plastic material, particularly glass fiber reinforced materials. Hybrid construction is very common, where steel parts are used in an aluminum mold to add strength to a slender feature, or parts of a steel mold are hardened to prevent wear at a rotating or sliding mold feature.

Examples are DIN 2344, and DIN 2767

Other Steel

For High gloss surfaces that can be polished to a Class 1 optic-quality finish we utilize S-Star and NAK 80 from Daido