To achieve efficiency and high-quality production, there are several considerations that should be made when optimizing part design for the injection molding process:

While quantitative production results have been excellent, ICON also enjoys the positive cultural impact at their company.  Automation goes hand-in-hand with their family-like culture of helping enable equal opportunities and more internal promotions.

These systems make use of mechanical motion to drive the pin into the mold cavity. As the mold opens, a mechanism is synchronised with it, causing retraction of the pin that holds back and lets loose the molded part. They are known for their reliability and precision especially in high-volume production environments. The key merit is that they have a long life span and can operate at very high speeds but there may be need to carry out extensive maintenance because they wear out regularly.

A: Side-actions use hydraulic pressure or mechanical means to move the core during injection. This helps in forming features that are perpendicular to the main parting line and must be removed from the part without causing damage to the mold surfaces.

The invention of plastic injection mold side actions has helped to make mold designs flexible and its functionality improved. Modern day side actions apply highly developed hydraulic and mechanical systems which allows core movements in the molding process as well as undercuts, aspects which are usually hard to pull off. These systems offer greater consistency, better precision and ensure that final products conform precisely to design requirements. Additionally, the recent developments have been driven by reducing cycle time while minimizing wear and tear on molds thus making them last longer and be more reliable as an instrument for injection molding. They have also seen the incorporation of real-time monitoring capability with smart sensors at peripheral devices that control these motions leading to efficient process control and scheduling with reduced downtime in case adjustments have to be made speedily. Manufacturers are now able to produce complex parts of high quality due to these improvements that meet various industries’ stringent criteria.

These side actions make possible complex high precision parts through intricate design otherwise not achievable by conventional two-part molds.

Kleitsch-Killam is seeing the benefits first-hand. “I oversee our Safety Committee, and I’ve seen injuries decline relating to this process. We're also getting a more consistent product and our Quality Department is seeing that we're checking these parts, we're noticing that they're better, they're more consistent, and it's allowing the work to flow faster.” In summary, “We’re getting these parts to the customer faster than ever before,” said Kleitsch-Killam.

Modular mold base systems have revolutionized injection molding by providing greater flexibility, cost savings, and reduced lead times. One primary advancement is fast interchangeability of molds parts that decreases production time loss thus boosting productivity. These systems also make customization easier for each specific project with adaptability without necessarily needing a new set of molds for different requirements. Further precision engineering advancements have been made so that modular mold bases now achieve increased levels of precision and strength resulting in consistent product quality. Additionally, through incorporating advanced materials as well as cooling systems into these bases; it has led to better cycle times which optimize this process by ensuring proper temperature control during injection molded parts processing step.

The spring-loaded type make it possible to hold cams pins in place while retracting them when necessary during die opening process by using springs.Therefore, one can argue that fixing these springs are less complicated compared to mechanical or hydraulic ones. The primary advantage derived from adopting such systems relates to low initial set up cost as well as ease of replacement although I think springs lack robustness exhibited by mechanical or hydraulic devices making them susceptible to wear down, hence limiting their applications under extreme conditions.

The detailed steps involved guarantee efficient production for high quality accurate parts through injection molding process every time it’s done consistently.In sum, proper execution of these stages gives assurance for cost-effective yet precise manufacture in good quantities consistently when performing injections molding operations at any given time

In summary, choosing an appropriate type of a cam pin system depends on various factors including specifications related with molded article, complexity attached with mould and size of batch which has to be manufactured.

A: Modular systems allow for more flexible and cost-effective tooling. They enable the creation of multiple parts or different part designs using interchangeable mold components, thus reducing overall tooling costs.

The post-installation service includes a dedicated customer success team, 24/7 remote monitoring and support, lifetime maintenance, and equipment repurposing services. All these services are included in ICON’s flat hourly rate. If the system stops performing, ICON stops paying.

A: Side-action injection molding is a specialized process used to produce parts with complex geometries. It involves the use of movable components called side-actions to mold undercuts or features that are perpendicular to the main parting line of the mold.

Following these key considerations assist designers and engineers in creating efficient, durable performance-oriented tools and moldings that result in high-quality components every time they are produced consistently throughout their lifecycle.

A: The main types of injection molding methods include standard injection molding, double injection, insert molding, and specialized processes such as side-action injection molding and the cam pin method.

To increase the ability for molding such complex parts, it is important to integrate advanced techniques and technologies. To begin with, multi-material injection moulding can greatly enhance functional capabilities and aesthetic appeal by forming materials having different properties into one part. On the other hand, before actual production takes place, High Performance Computing (HPC) simulations serve to optimize mold design as well as process parameters thereby reducing defects while improving general qualities. Finally, investing precision machining with high-accuracy CNC equipment ensure tighter tolerances as well as consistency in producing intricate features thus negating secondary operations; hence enhancing production efficiency.

On the whole, side-actions are very useful in expanding injection moulding capabilities by effectively addressing and controlling undercuts within mould designs so as to enable complex part creation.

Collapsible cores are advanced molding mechanisms designed to facilitate the creation of complex internal geometries, particularly for parts with undercuts or intricate internal features. These cores collapse inward during the part’s ejection phase, allowing easy removal from the mold without damaging the part.

Thus, by implementing them thoughtfully it will help designers build efficient molds with having side-actions, producing quality parts while maximizing production efficiencies themselves.

As ICON eyes expansion with a new facility and new, larger corporate customers, they continue to push the boundaries on their technical capabilities and production capacity. They now consider Formic a unique and powerful partner in their growth strategy.

While ICON’s wide variety of machines and services is a unique selling point for them, it was also a challenge in finding affordable, flexible automation solutions that they could trust to reliably work.

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These principles can be imbedded into mold designs whereby designers can come up with sturdy molds that give high quality parts repeatedly from cycle to cycle whilst shortening production cycle.

The injection molds’ longevity and optimal performance can only be achieved through proper maintenance and timely troubleshooting. There are several approaches for solving common mold problems outlined below:

“I think manufacturers are worried about replacing people. Another barrier to entry - It's expensive. It's not something you can go buy off the shelf, so you have to get a custom solution. It’s a whole ordeal of creating something specific, and especially as a custom injection molder, we are running different things in our presses every day. There are a lot of automation companies out there that are locking you into something.”

By maintaining their molds using these practices of maintenance and repair activities, manufacturers can increase their lifespan thus reducing downtime costs together with producing high quality parts.

A: The cam pin method involves using a cam pin to move the core or lifter into position during the injection molding process. This is especially useful for producing internal threads and other intricate features.

When ICON learned about Formic’s unique OpEx-based approach that brought an immediate ROI, their uncertainty around automation completely changed. Like most Formic clients, Galindo describes Formic as a zero-risk approach to automation that is almost “too good to be true”. "When we were considering Formic, it was all reward, no risks. I couldn't come up with a good reason to say no."

All in all, modular core compression side-action systems offer distinguished advantages such as high precision, flexibility, minimal maintenance downtime thus making them ideal for modern injection molding applications.

Multi-pronged strategy is required to make plastic injection molding more efficient. These are the current recommended strategies from top industry sources:

Addressing these challenges through creative solutions allows manufacturers to better integrate them into their molding processes, thereby improving functionality while managing costs and increasing productivity.

To address undercuts in mold design, side actions are important as they allow the creation of intricate geometries that could not be achieved through a standard two-part mold. These undercuts can make it impossible for a molded part to be removed from the mold without causing any damage due to their inward-facing angles or projections.

In side action injection molding, when mold is closed, it forms the mould cavity with the help of cams or slides known as side actions. The movement is made possible by angle pins which push the side actions into a position where they become accurate. After this, hydraulic or mechanical actuators that control the molding cycle make the side actions go back hence leaving space for part ejection. This process ensures that undercuts intricate geometries are created such that it does not damage the part hence improving design opportunities and quality of injection molded products.

Through integration of these advanced techniques, manufacturers are able to address undercut challenges as well as complex geometries more effectively resulting in better quality products at lower cost.

Formic’s automation service and value does not stop with the equipment installation. Formic provides post-installation services to ensure that clients get maximum round-the-clock uptime and benefits.

At ICON, this is only the beginning. Their automation and company growth journey is just getting started. In the past 3 years, they’ve doubled their machine count and opened a new warehouse space. They are now preparing to expand to a new (third) manufacturing facility later this year, which will house even higher-speed production and more technical capabilities for their customers.

Several trends are poised to redefine industry standards and practices as the sector of side action injection molding continues to develop. Integration of state-of-the-art automation and robotics, which enhances accuracy while reducing labor costs, stands out as a key trend. In addition, smart manufacturing technologies such as IoT and AI are on the rise thereby offering real-time monitoring, preventive maintenance capabilities that minimize downtime, and extend mold life. Moreover, innovation thanks to new high-performance materials has brought about more complicated and enduring components. Lastly, greener practices like biodegradable materials use and efficient energy consumption are being adopted due to sustainability focus. The overarching goal is improving the efficiency, quality and environmental responsibility in side action injection molding.

The effectiveness of side actions in mold design mainly relies upon a few key principles that contain the latest thoughts from top resources:

Hydraulic systems use fluid pressure to control cam pins hence rendering them slow and graceful movements. Such designs are also suitable in scenarios where there is need for larger forces or more delicacy like very large parts or those with intricate details. Consistency and repeatability of movement attained by hydraulic cam pins is its most prominent benefit though they require more complex setups and could be expensive due integral hydraulic components as well as maintenance requirements.

Generally, collapsible core enhances plastic injection molding flexibility and capabilities thereby enabling manufacturers to handle more sophisticated designs with efficiency and accuracy intact.

There’s enough buzz around robotic automation in recent years that most manufacturers have at least tossed around the idea of whether it’s right for them. If the idea of growing your bottom line while improving processes and reducing costs excites...

Thus these measures would enable manufacturers enhance their productivity, lowering costs as a result of more efficient plastic injection molding processes.

Amidst contemporary manufacturing, the most widely used and efficient technique is injection molding for creating intricate and complicated components. Amongst the many techniques employed in injection molding, side action injection molding is specifically known for its ability to create complex geometries and undercuts that would be difficult or impossible using traditional methods. This blog post aims to explore side action injection molding in details by giving a comprehensive account of its procedure, advantages, and applications. By understanding these intricacies, manufacturers can utilize this specialized technique in order to better their products’ precision and functionality thereby leading to enhanced performance and innovation across different sectors.

Whereas the use of collapsible cores can reduce secondary machining operations during injection molding process; thus saving time and costs. It also contributes to a better product quality as collapsing mechanism maintains delicate feature while ejecting it.

In the competitive manufacturing sector, there are few names that have risen as quickly as ICON Injection Molding. Founded in 2001 by three brothers with a wealth of industry experience, ICON has grown organically to become a go-to provider of custom plastic injection molding solutions. From medical devices to defense equipment for clients like Axon, they make plastic parts that proudly carry the ICON quality stamp and "Made in the USA" label for their customers.

Whenever it comes to the process of injection molding, side action mold design involves introducing lateral or side movements into molds which allows manufacturing of intricate parts having undercuts. This is done through the integration of cams or slides within the mold design which move sideways to the direction of opening and closing of a mold. These cams or slides are set into motion during a specific stage of a cycle when they enable formation and removal of parts that have challenging features which cannot be easily created through traditional straight-pull molds. The best suitable method for manufacture such parts could consist in projecting component surfaces at right-angles with respect to main mold parting line there could be projections, recesses or threads perpendicular to the main mold parting line on such molds

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Nicole Kleitsch-Killam, ICON’s Chief Administrative Officer, sits in the middle of everything at ICON, helping their people, their growth strategy, and their day-to-day operations. She has been with ICON for a majority of the company’s history and knows the barriers to automating.

“Growth is what we live for here at ICON,” says Kleitsch-Killam. “We're always looking to grow. It's about growing the business and bettering the families that work here and the community that we live in. And whatever industry that we can get into and grow in, we're looking to automation to help with that.”

Specifically, the Formic Tend™ system consists of a 6-axis articulated FANUC robot arm and vertical conveyor that fully automates the process of loading, unloading, and lowering the finished parts into a cooling bath for the final annealing process.

Without any capital investment or increase of in-house automation resources, ICON received a customized robotic machine operator for one of their injection molding stations. The solution combines a customized Formic Tend™ system and Formic’s production optimization services, all for $10 per hour of system usage.

A: Considerations include the complexity of the part, the type of material used, the required precision, and the specific features that must be produced. Additionally, the chosen method should balance production efficiency with tooling costs.

ICON’s reliable production for their customers was a profound result for Joel Robles, ICON’s Director of Operations. In discussing the benefits of the Formic system and partnership, he says “We definitely enjoy the fact that we have these long running jobs that now we can guarantee are going to run 24/7 as opposed to having to shut them down here and there depending on who showed up for the day.”

The methods employed in injection molding to build part quality and consistency require a holistic approach involving process control, design, and material choice. Here are some common practices which help manufacturers achieve parts of high quality that have uniformity:

A: Common challenges include managing the hydraulic pressure during injection, ensuring that the core deflection is minimized, and achieving precise molding to meet tight tolerances.

Not only did manual machine operation result in employee turnover and injuries, but it also taxed their business with operational inefficiencies and constrained production output.  While the injection molding machine had consistent cycle times, manual operators did not. The undesired results: unsafe work, inconsistent output, longer lead times, and higher prices for end customers.

In the modern mold design, Computer Numerical Control (CNC) technology is vital in improving accuracy, speed, and complexity in the production process. The CNC technology allows for detailed machining of complex mold components through employment of sophisticated software and automated machinery thereby ensuring consistency and quality of the product. One significant advantage associated with CNC technology is that it can be used to quickly prototype and manufacture custom parts thus reducing lead times and leading to faster iterations in the design stage. Moreover, automation afforded by CNC systems helps in minimizing human error hence making sure that molds are made as per exact specifications and tolerances. Also, it favors use of a variety of materials such as high-performance alloys and composites necessary for making durable, high quality molds. For instance, with its ability to streamline production workflows while ensuring high levels of accuracy, CNC technology is indispensable in meeting the intricate demands of present-day injection molding industry during mold design phase.

These approaches will allow manufacturers enhance their molded parts’ quality and consistency while improving performance and customer satisfaction.

Manufacturers can address ejection and perpendicular undercut problems by using these strategies in integration towards increasing process reliability as well as effectiveness.

A: Hydraulic pressure is often used to move the side-actions or cores during the injection process. It ensures that there is enough force to hold the core in place and produce parts with the required complexity without causing core deflection.

Several things must be thought of when comparing modular core compression side-action systems. These arrangements improve design flexibility and promote ease of use; in addition, they employ complex molding types and are used in high volume production plants. The systems are modular in nature, making it possible to quickly replace them so as to prevent long periods of repair. They are also known for performing well even when subjected to heavy molding pressures.

Another important technique is to have use of conformal cooling channels. The channels follow the geometry of the part allowing for even cooling as well as minimizing warping and defects. This approach also improves on the cycle time and general quality of the output.

Imagine standing on your feet all day, opening a machine door every few minutes, and retrieving a 300-degree hot, plastic part to place into a cooling bath. Then repeat this process again, for 8-10 hours straight (with a lunch break, of course).  At ICON Injection Molding in Phoenix, Arizona, this is exactly what some of their team members had to do every day.

Injection molding side actions are movable parts that slide in a direction perpendicular to the main axis of a mold. These cams or slides allow the creation of undercuts and other complex features found not in relation to the principal opening and closing direction of the mold. In injection molding cycle, these side actions engage at different positions to develop or release intricate characteristics on a part leading to production of components which would not be achieved through conventional techniques of molding. This helps in improving manufacturing advanced parts by increasing the design flexibility and accuracy in injecting molded products.

A: Precise molding ensures that the injection molded parts meet the desired specifications and quality standards. This is critical when the part must fit perfectly with other components or perform a specific function in a given application.

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Automating with Formic, the only question manufacturers need to ask themselves is: what repetitive manual tasks can be automated in my facility right now?

“We knew we had to look outside and see if anyone could come in and assist us with automating our machines,” Galindo said. They are a little bit older machines that we were looking to automate, so that brought in a lot of stumbling blocks.”

The main benefit of collapsible cores is that they can form high precision and complex shapes which would be difficult or impossible to achieve through traditional methods of molding. They have proved most helpful in situations where there are complicated part designs especially in areas such as motor vehicle industry, medical sectors and consumer good industries.

ICON’s automation partnership with Formic brought immediate benefits to their business, most notably, a 40% decrease in OpEx from the first day of usage.

“At ICON, it's really about creating a place where people from all walks of life can flourish,” says Kleitsch-Killam. “We’re so heavy on internal promotion. Almost all of our supervisory positions were filled with internal promotion in the last year, and about 80% of our management positions were also filled from internal promotion. It doesn't matter if somebody has a criminal history or they weren't successful at their last job. We are willing to give everybody the opportunity here at ICON and give them the training and the resources to build a career for their family.”

Dealing with undercuts and complicated geometries in the molding process involves selective application of sophisticated tools and methods. One way to do this is by using collapsible cores or slides and lifters, which can be moved in and out of position so that the part can come out without damaging its fine details. By doing these it enables successful molding of parts with internal undercuts or complex shapes that otherwise cannot be produced using a traditional mold design.

Every injection molding has cam pin systems which are important elements that allow for the manufacturing of complex geometries and side actions in moulds. Their main function entails lateral movement of the mold components for undercut release or elimination of side features from a part. In this paper we shall look at three widely-accepted types of cam pin systems:

Nicole Kleitsch-Killam, who also reviewed the Formic contract, felt the same positive reassurance. “The reason that we went with them is just the flexibility that they offer and their contract was not detrimental to us in any way. It didn't lock us into anything.  We went with Formic because it is a really symbiotic relationship for both of us.”

Enter Formic. Introduced to ICON by another automation vendor, Galindo recalls that the vendor recommended them and said “Hey, you’ve got to work with these guys.”

Not only is ICON’s Operations team seeing more consistent and faster per unit cycle times, but they have also increased total production time. Without being as reliant on hard-to-find labor, especially during 3rd shift, they are now predictably producing parts all day.

Hydraulic cylinders are important in the production of intricate injection-molded parts that have special features which cannot be made by a two-plate mold. Side actions are needed to make undercut or those features which are perpendicular to the direction in which the mold opens. The hydraulic cylinders help to push side cores or sliders into position during the injection stage and withdraw them at ejection time. Employing hydraulic power guarantees accurate, repeatable motion that preserves the complexity of molded features. Their capability to handle high-force applications makes them suitable for industrial applications as they guarantee dependability and efficiency when manufacturing intricately designed plastic components.

Moreover, advances in 3D printing technology have made it possible to produce molds with very complex geometries that correspond to specific features of a particular part. It allows designers to incorporate much finer details directly into their mold designs which greatly reduces subsequent machining or assembly operations.

In addition to gaining productive output, improving employee safety and product quality were other successful results of automating with Formic.

Side actions in undercut features are formed through motion from side action molds using cam mechanisms. These cams move laterally to position the sides accurately into the mold cavity because they are usually guided by inclined pins during die closure. In this way, misalignment is eliminated hence even complex geometry is correctly formed.

ICON also experienced increased and more consistent production. Where they previously depended on manual labor to load and unload parts with wide variability, ICON now has a reliable system that is doing the same task at a 30% faster cycle time.

Most small-to-medium manufacturers across America struggle with this exact problem, but they have not yet automated. Typical barriers include the lack of capital budget, high maintenance costs, the inability to use automation in dynamic and lower-volume processes, and the stigma of replacing manual workers with robots.

When molding process ends, these cam mechanisms enable the smooth retraction of side actions thus allowing safe removal of molded parts without any harm. This withdrawal relies on hydraulic or mechanical actuators to maintain uniformity and continue producing good quality end products. Generally, cam mechanisms make side action molds more functional and versatile so that intricate components can be obtained efficiently and accurately.

A: Tooling costs increase with part complexity. The need for specialized features like side-actions, cam pin actions, and intricate mold surfaces requires more advanced and expensive tooling capabilities.

Helping overcome these barriers and growing ICON’s business with technology is the main mission of Jeff Galindo, their Executive Operations Specialist. For the past few years, Jeff and the Operations team knew automation could help their business, but they didn’t have the technical resources to confidently implement it.

By focusing on these key design principles, manufacturers are able to optimize their injection molding process which consequently results in lowered production costs and improved quality and performance levels of molded parts generally.

While some manufacturers invest their capital in fixed equipment for 15 years, ICON signed a 3-year contract with Formic to evolve in a more agile way, but still get the economic benefits of increased production and lower manufacturing costs.

Kleitsch-Killam thinks robotic technology only enhances their mission. “Having this automation cell, it's a really beautiful piece of equipment out there and it's just a real showpiece. I hope to have other show pieces like that for people to see. And again, despite the stigma, it's not replacing people, it's enhancing our productivity. It's a productivity enhancer for our business and our people.”