CONSTRUCTION DEPARTMENT
The design department is a key place in ALKAZ Plastics. This is where designs, models, prototypes of manufactured parts, injection mold designs, and entire concepts of multi-element structures are created. All employees of this section are exceptionally competent and experienced in their field. Thanks to this, we can offer our customers professional and comprehensive service at every stage of production. In the design department, we employ specialists who make every effort to ensure that both designs and finished products meet all your expectations. We use proven programs, machines and tools that allow us to carry out various orders – from design, through 3D printing and plastic injection, to CNC services. At the beginning of each design project, we thoroughly familiarize ourselves with the client’s goals and requirements in order to prepare an offer that is ideally suited to their needs. We also develop a transparent cost estimate for the implementation of the design assumptions. As part of its activities, our design department deals with issues such as:
• design of details and parts
• 2D and 3D modeling
• rapid prototyping – 3D printing
• injection mold construction projects
• injection simulations
• cooling projects
• selection of product manufacturing method at the modeling stage
• cost estimation of entire projectsThe design process is complicated and requires not only theoretical knowledge, but also an extensive practical experience. For this reason, it is worth entrusting it to experts in the industry, including specialists from our company.
MOLD MANUFACTURING
ALKAZ Plastics increases quality and efficiency in the production of custom molds and products through rigorous engineering, solving molding problems and optimizing the efficiency of tool design and production. The injection mold structure and design directly influence various aspects of the final product, including its dimensional accuracy, surface finish, mechanical properties, and overall quality. A well-designed mold ensures that the plastic material flows properly into all areas of the cavity, cools uniformly, and can be easily ejected without defects. Factors such as the mold material, cooling system design, gate location, and runner system all contribute to the mold’s performance and, consequently, the quality of the molded parts. In this post, we will explore the injection mold structure in detail.
ALKAZ Plastics specializes in the design and production of molds for various applications, including automotive parts, medical devices, consumer electronics and industrial plastic components. We have an extensive experience in the production of precision molds for items such as automotive lighting, interior and exterior parts for electric cars and scooters, housings, transparent parts and demanding technical parts.
A high-quality mold production process is essential for the production of high-quality components while maintaining cost-effectiveness. By investing in the production of high-quality molds, the quality of the parts increases, while the overall project cost is reduced. The tool is usually made of two pieces of metal. A part-shaped cavity is cut into each side of the mold. The mold is usually made of aluminum, steel or alloy. Aluminum molds are cheaper to produce, but their durability is limited compared to steel molds and they must be replaced frequently. Steel molds can be repaired or modified by welding. High-quality steel molds can be used for up to a million cycles.
ALKAZ Plastics offers:
– prototype tooling, including prototype parts
– high-precision mass production molds
– multi-cavity molds and family tools
– precise and professional technical analysis, DFM, mold flow, feasibility study
– complex mold sets, for example 3D molds in one project produced in about 8-10 weeks
MOLD MAINTENANCE
Molds are a significant investment in the injection molding production process. The tools are also a key elements, as they are directly related to productivity, scrap rates, part quality, downtime and operating costs. Keeping molds clean and efficient is crucial to the profitability of a manufacturing operation.
LASER CLEANING OF INJECTION MOLDS
Spotless Mold Cleaning for Maximum Efficiency. At ALKAZ Plastics we know that clean injection molds are essential tools for manufacturing plastic parts. Dirty injection molds can lead to production issues and defects. Dirt and debris on the mold surface can prevent the plastic from bonding properly.
Dust or dirt interacting with the molten plastic during the molding process can lead to a variety of defects on the molded parts for instance:
– surface delamination
– black spots
– discoloration
– bubbles/voids, which can reduce strength and affect the appearance of the product
– in severe cases, dirt and debris can even damage the mold itself, requiring expensive repairs or replacement.
ALKAZ Plastics tool shop performs regular cleaning and maintenance to keep our clients’ molds in top condition. Currently, our tool shop takes pride in offering high-quality laser cleanig of injection molds. This technology provides residue-free cleaning to keep the molds in top condition. That is an extremely effective method of decontamining molds, because it removes unwanted materials such as resins, release agents, production residues, oxides and oils without damage to the underlying structure, or mold surface finish extending the lifecycle of the molds.
Laser cleaning is the most effective alternative to chemical cleaning, abrasive blasting, ultrasonic cleaning or other traditional methods.
KEY BENEFITS OF USING LASER to clean plastic injection molds include:
– Gentle cleaning for precision molds
– No wear and tear on the molds
– Reduced downtime in production
This cutting-edge technology can significantly extend the life cycle of our clients’ injection molds, and in particular improves component quality, increases production efficiency, reduces maintenance costs and reduces downtime.
