Sometimes cutting corners is the only way to reach your goals.
It’s true when it comes to making triangle-shaped toys and engineering products and parts used in the telecommunications, aerospace, medical and photonics industries.
Thankfully there are injection molding pros in Dallas-Ft Worth who know how to properly cut sharp, precise corners. If it weren’t for them, triangle-shaped toys would be non-existent and the world would go without many small parts that make big differences in people’s lives.
But it’s not easy to engineer sharp corners in plastic parts–even if you are using injection molding. There’s an array of things that can compromise the strength, accuracy and aesthetics of your part or product.
Here’s a look at some of the factors injection molding pros in Forth Worth consider–and combine with the proper placement of corner radii and fillets–to reduce the likelihood of something going wrong:
Material Selection
Some plastics are more amenable to being shaped into sharp-cornered parts and products. In general, plastics that do not contain glass or fiber (commonly called “unfilled plastics”) are better for creating sharp, strong corners. Plastics filled with glass or fiber are stronger than unfilled plastics, and resist being crammed into corners and wrapping around posts and wall intersections.
If you need sharp corners, make sure to select a material that is unfilled. It will increase the likelihood of success.
The Right Radius
Two types of radii matter when it comes to manufacturing injection molding plastic parts and products–internal and external.
The fillet radii are those at the bottom of compartments, where walls intersect with floors. The radii at the top of the walls don’t have a specific name, but they are equally important when creating molds.
Rather than designing a mold with incredibly sharp corners, the fillet radii should typically use a radius equal to at least .5 times the adjacent wall thickness. Top radii should be rounded to three-times that amount–or 1.5 times the thickness of the nearest walls.
Adding a little extra space strengthens your parts and products, eliminates residual stress and helps prevent cracking.
Manufacturing Methods
At the end of the day, it all comes down to the method of manufacturing. Without the ability to use alternative methods of manufacturing, internal corners of any mold cavity simply can’t be smaller than the radius of the end mill used to make them.
Working with a injection molding company in Dallas-Ft Worth that offers an array of manufacturing methods, specializes in small-form factor injection and has experience working with alternative methods of manufacturing is your best bet when it comes to successfully creating a product with sharp, strong corners.
Connect with Injection Molding Pros in Dallas-Ft Worth Today
If you are ready to start cutting corners and want to ensure success, connect with the custom plastic injection molding experts at QT Manufacturing today. They’ll help you choose the right material, find the right radii and figure out which manufacturing method is right for you. Call 972-221-0537 to get started with the injection molding pros in Dallas-Ft Worth today.
