Overcoming Challenges in Large Part Molding

Rob Osgood • September 18, 2024

In plastic manufacturing, molding large parts presents unique challenges that impact cost, quality, and production timelines. At AdvancTEK, we understand these complexities and work closely with our customers to navigate them effectively. From limited equipment availability to material handling difficulties, AdvancTEK leverages its expertise, advanced machinery, and innovative solutions to turn challenges into opportunities for success. 

Common Challenges in Large Part Molding 

Our customers often face several challenges when it comes to large part molding. One of the biggest is finding suppliers with the capacity to handle large molds. As injection mold tonnage increases, the availability of suitable equipment and suppliers diminishes, driving up costs and extending timelines. At AdvancTEK, we address this by maintaining a robust inventory of large tonnage machines across our facilities in the U.S. and Mexico, ensuring we can support projects regardless of location. 

Material handling also poses significant hurdles due to the sheer size and weight of large parts. AdvancTEK uses 6-axis robots to safely and efficiently transport parts from the press to the operator, minimizing human error and enhancing consistency. Additionally, our well-coordinated materials and logistics team ensures a seamless flow of parts, preventing bottlenecks and avoiding the need for excessive warehousing. 

Logistics can be another challenge, especially when dealing with molds weighing up to 80,000 lbs. AdvancTEK’s facilities are equipped with cranes capable of handling these weights, making it easier to move large molds and streamline the production process. 

AdvancTEK’s Advanced Machinery and Equipment 

AdvancTEK boasts an impressive lineup of 11 injection mold machines over 1,450 tons, including four machines with capacities exceeding 3,000 tons and a maximum capability of 3,500 tons. Our crane capacities, ranging up to 40 tons in Mexico, further enable us to manage the heavy molds required for large parts. 

We have successfully leveraged this equipment to tackle unique molding challenges. For instance, an EV customer required a very large one-piece part that initially seemed to need 4,000 tons of clamping force. By strategically adding more sequentially activated drops and adjusting wall thickness, we reduced the tonnage requirement to 900 tons, demonstrating our ability to optimize the molding process for efficiency and cost savings. 

Importance of Material Selection 

Material selection is pivotal in the success of large part molding projects. The choice of material can significantly impact the required clamping force and, consequently, the type of machines that can be used. At AdvancTEK, we access a comprehensive material library to identify resins with superior flow characteristics, which can help fill large parts more efficiently and enhance their aesthetics. 

Even within specific resin families, choosing the right material can make a substantial difference. Our expertise in material selection allows us to offer solutions that reduce required tonnage, open up more machine options, and ensure the highest quality outcomes. 

Ensuring Repeatability and Consistency 

Consistency is key in large part molding, and AdvancTEK employs several techniques to ensure repeatable, high-quality results. Rigorous Design of Experiments (DOE) are conducted with each new mold to establish precise process parameters. Using RJG cavity pressure sensors combined with eDart technology, we constantly monitor these parameters and set machine alerts for any deviations. 

This proactive approach extends to our automated handling systems, where 6-axis robots are programmed to isolate any parts that do not meet our strict quality criteria, preventing defective products from reaching the customer. 

Cost Efficiency Strategies in Large Part Molding 

Cost efficiency is a priority for many customers, especially when dealing with large parts. AdvancTEK employs various strategies to optimize costs, such as adjusting wall thickness to reduce the need for high-tonnage machines. Using lower tonnage equipment reduces overall production costs while maintaining high-quality standards. 

Our use of 6-axis robots further supports cost efficiency by enhancing safety, reducing labor costs, and maintaining consistent product quality throughout the production process. 

Advantages of Choosing AdvancTEK for Large Part Molding 

Working with AdvancTEK offers several key advantages. Our multiple large tonnage machines located in both the U.S. and Mexico provide a significant edge in contingency planning, a critical consideration in today’s global manufacturing environment. Should a disruption occur at one facility, we can quickly transfer tooling or share the workload with another, minimizing downtime and ensuring continuity. 

Additionally, our in-house tooling, design, and process engineering capabilities allow us to handle every aspect of large part molding, from initial design to final production. Our expertise spans three different plastic processes (injection molding, thermoforming, RIM), giving us the flexibility to select the best approach for each project. 

Misconceptions About Large Part Molding 

There are several misconceptions surrounding large part molding. One common mistake is oversimplifying the required tonnage. Factors like material type, wall thickness, and gating play crucial roles in determining the size of the machine needed. Our team at AdvancTEK conducts detailed mold flow analysis and simulations to optimize each project, ensuring the most efficient use of equipment. 

Another often overlooked aspect is the cost and logistics of shipping large molds. Moving these molds requires careful planning, the right type of trailer, and cranes for loading and unloading. AdvancTEK’s extensive experience and logistics capabilities help manage these challenges effectively. 

Conclusion 

Molding large plastic parts requires overcoming a unique set of challenges, from equipment availability to material selection and cost management. At AdvancTEK, our expertise, state-of-the-art equipment, and innovative problem-solving approach empower our customers to succeed, no matter how complex the project is. 

If you’re facing challenges in large part molding, contact AdvancTEK today to discover how our comprehensive capabilities can help you achieve your manufacturing goals.