BASED IN
SHENZHEN CHINA
AND THE USA
SHENZHEN CHINA
AND THE USA
Karl provides design review services for new molds
Checklist
General Information
- The most important aspect of our process is leveraging years of experience to thoroughly analyze the mold and ensure it will run smoothly and reliably for an extended period. While checklists are valuable, they cannot replace the insights gained from hands-on experience and in-depth industry knowledge.
- Karl also utilizes a checklist for mold design reviews.
- Below are just some of the fundamental items reviewed during our mold design analysis.
- We create a PowerPoint presentation based on the 3D mold design.
- The PowerPoint includes section views of the stationary and moving halves.
- Additionally, a screenshot of each mold component is placed on a separate slide.
- Comments are then added to the PowerPoint to suggest improvements.
- By providing a PowerPoint, customers can quickly examine the mold design without needing to open the large 3D mold design file.
- If the customer has a document specifying their mold standards, we will check the mold design for compliance with their requirements
Checklist
General Information
- Customer name and address
- Mold design review conducted by
- Date
- Product number
- Product name
- Product revision
- Product 2D file name
- Product 3D file name
- Product weight
- Plastic material
- Quantity required per year
- Quantity required for mold lifespan
- Quantity covered under mold warranty
- Brand
- Model number
- Manufacturing date
- Tonnage
- Tie bar distance
- Maximum daylight
- Minimum mold height
- Maximum mold height
- Shot size
- Screw diameter
- Nozzle orifice
- Ejector stroke
- Ejector connection type
- Electric or hydraulic
- Mold installation method (clamps or other)
- Can the machine display screw position, pressure, and screw speed curves?
- Required cycle time
- Shrinkage
- Product removal (robot or free drop)
- Robot end-of-tooling (EOT)
- RJG pressure sensors
- Are the molding machine platens shown in the 3D mold design?
- A-side mold weight
- B-side mold weight
- Total mold weight
- Is the mold weight suitable for the crane?
- Locating ring specifications
- Sprue radius and orifice
- Clamping does not interfere with waterlines or other components
- Mold can be clamped without issues
- All components fit within the clamp plate area
- All plates chamfered
- Parting line locks
- Pry bar slots
- Mold identification plate
- Eyebolt locations (ensuring level lifting of both halves and individual halves)
- Eyebolt holes in all plates
- Safety straps
- Mold base material and hardness
- Mold base relieved at the parting line
- Parting line location approved
- Surface contact area of the parting line
- Offset leader and ejector return pins
- Leader pins engage first
- Metric or inch units
- All metal types laser-marked with material and hardness
- Proper size and location of cavity identification, part numbers, and date codes
- Cavity plate thickness
- Leader pin debris slots
- Cavity material and hardness
- Shutoff angles
- Dowel pins
- Surface finishes
- Draft angles
- Vents
- Coatings (TiN, DLC, Electroless Nickel)
- Spare parts
- Core plate thickness
- Support pillars
- Core material and hardness
- Shutoff angles
- Dowel pins
- Surface finishes
- Draft angles
- Vents
- Coatings (TiN, DLC, Electroless Nickel)
- Spare parts
- Mechanical, hydraulic, or pneumatic operation
- Slide retainers
- Slide angle pins
- Lifters
- Hydraulic fitting type
- Hydraulic flow separator
- Parting line lock method for side actions
- Slide, gib, and wear plate material and hardness
- Shutoff angles
- Dowel pins
- Surface finishes
- Draft angles
- Vents
- Coatings (TiN, DLC, Electroless Nickel)
- Spare parts
- Lifters
- Cooling channels
- Cooling medium (oil or water)
- Hose temperature rating
- Insulator plates
- Baffles
- Cycle time optimization analysis
- Water connectors
- Engraved inlets and outlets
- Water manifold
- Mold flow analysis
- Hot manifold system
- Hot half supplied by hot runner company or mold maker
- Can the cavity plate be pulled from the hot half while in the machine?
- Hot runner electrical connections
- Pneumatic circuits (individual?) and connector types
- Valve gate system
- Valve gate precision (jig ground)
- Valve gate actuation (pneumatic or hydraulic)
- Open nozzle design
- Gate size, style, and location
- Cold runner design
- Runner puller
- Sprue puller
- Can the molding machine nozzle reach the sprue bushing?
- Are runner shutoffs required?
- Ejector housing cover
- Ejector plate switch
- Ejector pins
- Precision-ground ejector pin holes
- Consideration for grease-free operation
- Ejector springs
- Ejector stroke
- Ejector plate guides
- Dowel pins
- Ensuring part sticks to the correct mold side
- Adequate number of ejector pins, blades, and sleeves
- Guided ejection
- Stop pads
- Sufficient slide and/or lifter travel to ensure full part ejection
- Must include every mold component
- Must contain:
- Part number
- Company name
- Distributor name, location, and contact information