In our core expertise of injection mould toolmaking and plastic injection moulding, we encountered a critical need to innovate. Our task centered on designing a two-impression injection mould, transitioning from Ethylene Propylene Diene Monomer (EPDM) to Thermoplastic Elastomer (TPE). Crucially, this transition demanded not only material adaptation but also a significant reduction in cycle time to ensure project viability. Our target: achieve an overall cycle time of 60 seconds, effectively doubling output and eliminating the need for continuous manual labour at the moulding machine.
Our journey began with meticulous material selection. Evoprene G3462 emerged as a promising candidate, given its past success in similar transitions. Considering factors like shrinkage and post-moulding behaviour, we settled on a shrinkage rate of 1.5%, ensuring flexibility for adjustments post-trial without compromising integrity.
Anticipating challenges inherent in material transition, we meticulously designed the mould, prioritising 'metal safe' construction to facilitate cost-effective modifications post-trial. Our focus extended to ensuring the new material's ability to maintain shape under usage conditions, crucial for seal effectiveness. Through iterative trials and adjustments, we fine-tuned the mould design to align with stringent specifications.
The culmination of our efforts yielded remarkable results. Material trials confirmed that post-moulding shrinkage closely matched our design specifications, eliminating the need for post-trial resizing. Crucially, the seal's ability to maintain shape under real-world conditions exceeded expectations, ensuring optimal performance over time.
Our successful transition from EPDM to TPE not only met project objectives but also paved the way for future applications across diverse product lines. By achieving our target cycle time and implementing fully automatic operation, we not only doubled output but also streamlined production processes, reducing reliance on manual labour and enhancing overall efficiency.
In conclusion, this case study highlights our commitment to innovation and excellence in injection mould toolmaking. Through meticulous planning, strategic adaptation, and relentless dedication, we not only addressed immediate challenges but also positioned ourselves for continued success in a rapidly evolving industry landscape.
