A core insert of a multi-cavity thin wall packaging mold. The fixtures are made by Moulexpert. With 3+2 axis machining, multiple angled holes drilling, rough machining and some finishing can be achieved on five sides in only one or two set-ups. These holes are very common in this kind of tool (up to 100 holes in complex designs) and are used for cooling, venting, hydraulic circuits, ejectors, components assembly and others.
For smaller parts on its high-speed CNC machining center, Moulexpert utilizes a BRISC magnetic table.
The final product, a high performance six-cavity mold for thin wall packaging containers.
Manufacturing engineering team at Moulexpert.
Moulexpert, Inc. has the goal to be a leader in the manufacturing of thin wall packaging molds. To achieve this goal the company needed to accomplish the following:
- Increase productivity by reducing activity with no added value (set-up, move from work center to another, switch side, etc.)
- Reduce lead time
- Focus on its core business of thin wall packaging molds (injection).
Moulexpert began by selling two of its older 3-axis CNCs to make more space for a new 5-axis machining center. New investments included the AgieCharmilles Mikron 5-axis HPM 1350U and CAMplete software for simulation and post-processing. The company also created an improved layout for the plant, which included a CMM room near the new CNC machine tool.
"The 5-axis machining center has high torque and has the precision required for thin wall packaging molds," said Steve Nadeau, General Manager. "The machining center has a good table and XYZ size and supports the heavy weight of the molds.
"We save a lot of time because the parts stay on the machine for some time and there is almost no down time with the tool changer. Lead time is reduced in the same way. Highly skilled workers are difficult to find in mold making, so the 5-axis machine helps to transfer complex manual work."
CAMplete software for simulation and post-processing was selected for the following key features:
- Generation of error free code tailored to the machine installed on the floor (not generic) from any CAM system from the day of installation of the software (post developed with the machine tool builder)
- Proper G-code verification with manufacturer provided 3D machine models to prevent collisions (same 3D models that are used to build the machines)
- Optimization of that code (tool lengths, fixture heights, feedrates, etc.)
"CAMplete made a difference," said Nadeau. "We started the machine as soon as it was installed and there were no post-processor problems. There have been no collisions so far. The employees are happy because it is a viewer. There is less down time for alarm. The software features CNC, post-processing and simulation in the same box. It is a plug & play solution."
According to Nadeau, multi-cavities mold in hardened H13 for thin wall packaging can now be produced in 12 - 14 weeks. Types of material typically utilized by the company include P20, H13 and Moldmax XL.
Moulexpert machining capabilities include: 5-axis, 50 HP, 15,000 RPM; 3-axis high-speed machines, max. 42,000 RPM; 4-axis EDM; and CMM. Other capabilities include CAD/CAM, grinding, sawing, finishing, laser micro-welding and more.
Founded in 2001, Moulexpert provides:
- Multicavity molds with or without hot runner
- Stack molds with sprue bar and hot runner
- Thin wall injection molds
- Custom molds
- Single cavity molds
- High-performance and precision molds.
For more information contact:
Steve Nadeau, General Manager
Moulexpert, Inc.
415 3e Avenue
Levis, Quebec
Canada, G6W 5M6
418-834-5544
info@moulexpert.com
www.moulexpert.com
Jeff Fritsch
CAMplete Solutions Inc.
120 Otonabee Drive
Kitchener, Ontario
Canada, N2C 1L6
519-725-2557 x5333
jeff@camplete.com
www.camplete.com