When designing a mould, several factors need to be considered to ensure efficient production of high-quality parts. These considerations help minimize costs and potential defects.
What are the 9 Key Considerations for Mould Design?
1. Force Distribution
Moulds should be designed to apply forces over large areas. This helps avoid localized stress concentrations, minimizing tensile stresses and preventing material failure.
2. Geometry and Stress Conversion
Avoid sharp corners and edges in the design. Convert tensile stress into compressive stress through techniques like compressive pre-stressing to enhance part durability.
3. Material Flow and Densification
Ensure the mould facilitates good material densification. Avoid sudden changes in cross-section to maintain structural integrity and even material distribution.
4. Finishing and Machining
Prefer green machining over final finishing to reduce costs and time. Design should allow only small, limited machined surfaces and define non-machined roundings and chamfers.
5. Manufacturing Specifics
Pay attention to specific manufacturing steps like wet and dry pressing, extrusion, sintering, and glazing. Ensure the mould is compatible with these processes.
6. Removal from the Mould
Design should facilitate easy removal without damaging the part. Avoid thin walls as they can deform or break during removal.
7. Special Manufacturing Processes
For processes like CIP (Cold Isostatic Pressing), design should be scalable and flexible. Reusable tools can significantly reduce costs compared to processes like P-HIP.
8. Sintering Considerations
Incorporate features like spacers, support ribs, and special setters to prevent issues such as warping and sagging during sintering.
9. Material Properties
Consider material properties like moisture absorption, fluidity, and decomposition tendency. For materials prone to decomposition, design a heated mould with a low-resistance gating system.
Continue exploring, consult our experts
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