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Subtractive Manufacturing: What You Need to Know?

Learn more about what is subtractive Manufacturing:

Subtractive manufacturing is a process where material is removed from a solid block, bar, or sheet of material to create a desired part or product. This contrasts with additive manufacturing, where material is built up layer by layer to form an object. In subtractive manufacturing, tools like drills, lathes, and mills cut away material to achieve the final shape.

Common materials used in subtractive manufacturing include metals (such as aluminum, steel, and titanium), plastics, and composites.

How Does Subtractive Manufacturing Work?

Subtractive manufacturing typically involves CNC machines, which are highly automated tools capable of cutting, drilling, milling, or grinding away excess material from a workpiece. Here's a simplified version of the typical workflow:

1.Design Phase (CAD): The process starts with a 3D CAD model. This digital file represents the final part and is the blueprint for the manufacturing process.

2.CAM Software: The CAD model is imported into - CAM software, which generates instructions for the CNC machine, detailing tool paths, cutting sequences, and more.

3.Machining: The CNC machine executes these instructions, removing material from the workpiece using cutting tools like end mills, drills, or lathes. The machine works layer by layer or face by face, gradually refining the part.

4.Post-Processing: After machining, the part may undergo additional steps like polishing, deburring, or surface treatments to achieve the desired finish and tolerances.

Common Subtractive Manufacturing Techniques

Several techniques fall under the umbrella of subtractive manufacturing. Some of the most widely used include:

1.CNC Milling

In CNC milling, spinning cutting tools remove material from the workpiece, often from different angles. This process is ideal for making complex shapes, detailed surfaces, and precise parts.

2.CNC Turning

Turning involves spinning the workpiece while a fixed cutting tool removes material. This process is commonly used to make round items like shafts, bolts, and bushings.

3.CNC Drilling

Drilling uses a rotating tool to make holes in the workpiece. CNC drilling is accurate and can create holes of different sizes and depths, with the same results every time.

4.CNC Grinding

Grinding uses an abrasive wheel to remove small amounts of material and is often used to get smooth surfaces or very precise sizes.

Applications of Subtractive Manufacturing

Subtractive manufacturing is utilized across many industries where precision, durability, and high-quality finishes are critical. Here are a few examples:

Aerospace: Components like turbine blades, brackets, and engine parts are often made using CNC machining due to the need for tight tolerances and high-performance materials.

Automotive: Subtractive methods are used to produce engine blocks, transmission parts, and other vital components.

Medical Devices: CNC machining is essential for producing surgical tools, prosthetics, and implantable devices with precision.

Consumer Electronics: Custom enclosures, heat sinks, and other intricate parts can be crafted through subtractive manufacturing.

Advantages of Subtractive Manufacturing

1.High Precision

Subtractive manufacturing methods, particularly CNC machining, offer unparalleled accuracy and tolerances. This makes it the go-to choice for industries that require exact specifications, such as aerospace and medical device manufacturing.

2.Excellent Surface Finish

Because subtractive processes gradually remove material with fine-tuned tools, the resulting surface finishes are often superior to those achieved with additive manufacturing. This reduces the need for extensive post-processing.

3.Material Variety

Subtractive manufacturing can work with a wide range of materials, from metals and plastics to advanced composites. The flexibility to choose from different materials allows for parts with specific properties like strength, heat resistance, or lightweight construction.

4.Scalability

Subtractive manufacturing is ideal for both prototyping and high-volume production. Once the design is set, CNC machines can produce large quantities of parts quickly and consistently.

5.Established Technology

The maturity of subtractive manufacturing technology means it's a trusted, reliable option for many manufacturers. The tooling, machines, and software used have been refined over decades, leading to increased efficiency and lower costs over time.

Here are some Limitations of Subtractive Manufacturing

While subtractive manufacturing has many strengths, it also comes with a few limitations:

Material Waste: Since material is removed during the process, it naturally creates more waste compared to additive methods. Processes like CNC machining can produce a lot of leftover material.

Complexity Limits: The removal of material throughout the process generates more waste than additive processes. CNC machining, for example, might result in a large amount of excess material.

Setup Time and Cost: While CNC machines are fast and accurate, they require time to set up and program for new designs, especially for one-off or low-volume parts.

Subtractive vs. Additive Manufacturing

In recent years, the rise of additive manufacturing (3D printing) has prompted comparisons between the two approaches. So, how do they stack up?

Precision: Subtractive manufacturing generally offers higher precision and better surface finishes than 3D printing.

Material Options: Subtractive processes work with a broader range of materials, especially high-performance metals.

Waste: Additive manufacturing produces less material waste since it builds parts layer by layer.

Complexity: Additive manufacturing can produce more intricate internal geometries that may not be possible with subtractive methods.

Cost: For large-scale production runs, subtractive manufacturing is often more cost-effective, whereas additive methods shine for custom, low-volume parts.

Subtractive manufacturing is still an important part of today’s production, especially for industries that need high accuracy, flexibility with materials, and the ability to scale. While additive manufacturing (like 3D printing) is great for making complex, custom parts, subtractive methods such as CNC machining provide unmatched precision and smooth finishes.

Whether you’re prototyping a new design or producing thousands of parts for mass production, subtractive manufacturing provides a reliable and proven solution for your manufacturing needs. As the technology continues to evolve, its integration with other processes will only expand its capabilities, ensuring it remains a cornerstone of modern industry.

Do you want to learn more about subtractive manufacturing? Talk to an expert now, email us at info@hlhrapid.com or submit your CAD File here.

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Flame-retardant plastics are important for making products safer from fire in industries like electronics, automotive, and construction.

These special plastics help slow down or stop fires from starting. When combined with injection molding—a fast and efficient way to make plastic parts—flame-retardant plastics are used to create fire-safe products.

But what exactly happens during the injection molding process with these materials? Let’s look at the key points.

1. What Are Flame-Retardant Plastics?

Flame-retardant plastics are types of plastic that are specially treated to resist catching fire and slow down the spread of flames. These plastics are mixed with special chemicals that either stop the fire from starting or create a barrier to keep the fire from spreading. Some common flame-retardant additives include:

Halogenated compounds (chlorine, bromine)

Phosphorus-based compounds

Metal hydroxides(aluminum, magnesium)

Silicone-based flame retardants

Each type of additive offers different levels of effectiveness, safety, and environmental impact, influencing how the plastic will behave in various applications.

2.Why Use Injection Molding for Flame-Retardant Plastics?

Injection molding is a manufacturing process that allows for the high-volume production of plastic components with consistent precision and quality. For flame-retardant plastics, this process offers several advantages:

-Cost efficiency - Injection molding is ideal for large production runs, reducing costs per unit.

Design flexibility - Complex shapes and intricate designs can be easily produced.

Material efficiency - The process minimizes material waste, which is important when using expensive flame-retardant additives.

Additionally, injection molding ensures that the flame-retardant properties are uniformly distributed throughout the plastic component, which is crucial for meeting safety standards.

3.Processing Challenges with Flame-Retardant Plastics**

While injection molding offers many benefits, processing flame-retardant plastics comes with its own set of challenges. These include:

-High melt temperatures: Flame-retardant additives often require higher processing temperatures, which can lead to material degradation if not carefully controlled.

-Increased viscosity: Some flame-retardant additives make the plastic more viscous, affecting the flow during molding and potentially leading to defects like incomplete filling or surface marks.

-Wear on equipment: Certain additives, especially halogenated compounds, can be abrasive, causing wear and tear on molding equipment.

To overcome these challenges, manufacturers need to fine-tune their injection molding processes, including temperature control, mold design, and maintenance of the machinery.

4.Popular Flame-Retardant Plastics for Injection Molding

Different industries require different types of flame-retardant plastics depending on their application. Some of the most commonly used flame-retardant polymers in injection molding include:

ABS (Acrylonitrile Butadiene Styrene): Widely used in electronics and automotive components due to its good balance of toughness and flame resistance.

Polycarbonate: Known for its transparency and high impact resistance, polycarbonate is used in products like electrical housings and safety glasses.

Nylon (Polyamide): Common in automotive and industrial applications, flame-retardant nylon offers excellent mechanical strength and heat resistance.

PVC (Polyvinyl Chloride): Used in construction materials and electrical components, PVC is naturally flame-retardant but often enhanced for specific safety standards.

Each of these materials brings its own strengths to the table, depending on the specific needs of the product.

5.Applications and Industry Standards

Flame-retardant plastics are crucial in industries where fire safety is a priority. Some of the key applications include:

Electronics: Smartphones, laptops, and household appliances all rely on flame-retardant plastics to prevent electrical fires.

Automotive: Components like dashboards, connectors, and battery housings in electric vehicles require flame retardancy to meet safety regulations.

Construction: Building materials such as insulation panels, pipes, and electrical enclosures need to meet fire safety standards.

Products made from flame-retardant plastics must also comply with strict industry standards like **UL 94**, which tests for the flammability of plastic materials, and RoHS**, which regulates the use of hazardous substances, including certain flame-retardant additives.

6.The Future of Flame-Retardant Plastics in Injection Molding

As environmental concerns grow, there is a push toward more sustainable flame-retardant solutions. Traditional halogenated flame retardants, while effective, can be harmful to the environment and human health. This has led to the development of **halogen-free** flame retardants that are safer and more eco-friendly.

Additionally, advances in injection molding technology, such as **smart manufacturing** and **3D printing**, are enabling more precise control over the production process, leading to more efficient use of flame-retardant materials and reduced waste.

Injection molding of flame-retardant plastics is an important process for making safe products in industries where fire risks are a concern. Manufacturers need to choose the right additives and fine-tune the molding process to create high-quality, fire-resistant products. With new materials and technology, flame-retardant plastics are becoming more innovative and eco-friendly, helping improve fire safety standards in many industries.

Whether you're a manufacturer, designer, or a company who has questions related to injection moulding. Feel free to consult to us and upload your files here.  

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Everything You Need to Know About Bead Blast Finish in Rapid Prototyping

Rapid prototyping is a modern manufacturing method used to create physical models from digital designs.

Here’s a quick view of what is rapid prototyping:

By utilizing methods like 3D printing, CNC machining, or vacuum casting, it allows engineers and designers to transform CAD files into prototypes within hours or days. This process speeds up product development by allowing for repeated adjustments, testing, and improvements at a lower cost.

Rapid prototyping supports the evaluation of a product’s design, fit, and functionality before committing to full-scale production. It is widely used in industries such as aerospace, automotive, and consumer electronics to enhance innovation and reduce development time.

When it comes to rapid prototyping, choosing the right surface finish can make a big difference in the look and feel of your part. One popular option is the - bead blast finish, known for providing a smooth, matte surface. But what exactly is it, and why is it so commonly used in prototyping?

What is Bead Blast Finish?

Bead blasting is a surface treatment process that uses small, round particles (or "beads") to gently wear away the top layer of a material. The beads are typically made of glass, plastic, or metal, and they are blasted at the material's surface using high pressure. This results in a -matte finish, that is smooth to the touch, free from shiny spots or uneven textures.

In rapid prototyping, bead blasting is usually applied after parts are machined or 3D-printed to improve their appearance and feel.

Key Benefits of Bead Blast Finish

1. Smooth, Matte Surface: The main appeal of bead blasting is the sleek, non-reflective finish it provides. This can make parts look more professional and less rough compared to raw, untreated surfaces.

2. Removes Imperfections: Prototyped parts may have light imperfections or tool marks. Bead blasting helps to smooth out these blemishes, creating a more uniform surface.

3. Improves Grip: Bead blasting can also enhance the texture, providing a slight grip which is useful for prototypes of products that will be handled frequently.

4. Wide Material Compatibility: This finish can be applied to a variety of materials commonly used in prototyping, including metals like aluminum and steel, as well as plastics.

How is Bead Blasting Used in Rapid Prototyping?

After a prototype is made, whether by CNC machining, 3D printing, or injection molding, the surface may not always meet aesthetic or functional requirements. That’s where bead blasting comes in. Here's a simple breakdown of the process:

1. Preparation: The part is cleaned and prepared for blasting. Any delicate or critical areas may be masked off to prevent unnecessary wear.

2. Blasting: Beads are shot at the part’s surface at high pressure. The size and type of beads, as well as the pressure used, can be adjusted based on the material and desired outcome.

3. Post-Blast Finishing: Once blasting is done, the part is cleaned to remove any remaining media. Depending on the part’s purpose, additional finishes like anodizing or painting may be applied afterward.

In rapid prototyping, the bead blast finish is a valuable tool for creating smooth, attractive parts quickly and affordably. It’s a versatile method that works on various materials and can transform rough prototypes into presentation-ready products. Whether you’re working with metals or plastics, bead blasting is a finishing technique worth considering for your next prototype.

If you’re prototyping a part and want it to have that professional matte look, bead blasting could be the perfect finishing touch!

If you have questions about rapid prototyping or bead blasting, you may contact us at info@hlhrapid.com or simply submit your CAD file here: https://hlhrapid.com/instant-quote/

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How to Improve the Quality of Plastic Injection Molds?

Do you want to make high-quality plastic parts with injection molding? Curious about how mold quality impacts the final product? What can you do to ensure your molds give the best results? Let's check out the factors to improve the quality of your plastic injection molds.

Plastic injection moulding is a key method used to manufacture everything from little plastic parts to significant components. High-quality moulds are important for achieving the greatest outcomes. The quality of the mould has a direct influence on the finished product, from its appearance to its strength and durability. Here are some practical methods you may take to boost the quality of plastic injection moulds.

1. Choose the Right Material

The quality of your mould begins with the material you employ to create it. The mould material should be strong and resistant to damage, especially if you're making a big number of pieces. Hardened steel, stainless steel, and aluminium are examples of commonly used materials. Steel is more costly, but it has more durability and can generate higher-quality parts over time.

2. Design with Precision

A well-designed mould is necessary to deliver high-quality results. Pay particular attention to design elements like wall thickness, cooling channels, and draft angles. Proper design ensures that the plastic flows smoothly throughout the mould, lowering the possibility of flaws such as warping or partial filling. Use modern CAD (Computer-Aided Design) equipment to generate accurate and detailed designs.

3. Use High-Quality Injection Machines

The quality of the injection moulding machine has an important impact on the overall quality of the mould. Ensure that your machines are properly maintained and calibrated. Machines with upgraded controls can deliver more constant pressure and temperature, which are critical for making high-quality moulds.

4. Implement Rigorous Quality Control

Quality control is essential at every stage of the injection molding process. Regularly inspect molds for wear and tear and check the finished products for any defects. Using tools like Coordinate Measuring Machines (CMM) can help in accurately measuring parts and ensuring they meet specifications.

5.Optimize the Cooling Process

Cooling is a critical phase in injection molding that affects the quality of the final product. Uneven or inadequate cooling can lead to defects such as warping or shrinkage. To optimize cooling, ensure that the cooling channels in the mold are well-designed and that the coolant flows efficiently throughout the mold. Using conformal cooling techniques, where cooling channels are designed to follow the shape of the part, can further enhance the cooling efficiency.

6. Use Proper Mold Maintenance

Regular maintenance of molds is key to extending their life and ensuring consistent quality. Clean the mold regularly to remove any residues or buildup. Also, inspect the mold components like ejector pins and slides to ensure they are functioning properly. Lubricate moving parts to prevent wear and replace any worn-out components promptly.

 7. Control Injection Parameters

The parameters used during the injection process, such as temperature, pressure, and injection speed, significantly affect the quality of the molded parts. Fine-tuning these parameters can help reduce defects and improve overall product quality. Consider conducting trials to determine the optimal settings for your specific mold and material.

To improve the quality of plastic injection molds, use the right materials, design them accurately, use good machines, and maintain strict quality control. Regular maintenance and having skilled workers also help in making high-quality molds. By paying attention to these factors, you can produce parts that meet or exceed your quality expectations.

If you would like to discuss your requisites with one of our experts. You can submit you files here  and our team will contact you as soon as possible.

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Factors to Consider When Choosing Materials with CNC Rapid Prototyping

In this article, factors to consider in CNC Rapid Prototyping will be outlined to further assist businesses make the best decision for all the project needs.

When working on a new product, CNC fast prototyping is an excellent approach to quickly turn your ideas into actual products. This approach is popular among designers and engineers due to its precision, speed, and flexibility. However, one of the most important considerations you will have to make is which material to use for your prototype.

The material you choose might have a significant impact on the quality of your prototype.

1. What’s the Prototype For?

Before you begin selecting materials, you must first determine exactly what your prototype will be used for. Is it intended to be an operational version that can withstand pressure and testing, or is it only a visual model to showcase the design? The aim of your prototype will influence your material selection.

Working Prototypes: If your prototype needs to function like the final product, you’ll need strong, durable materials like aluminum or steel.

Visual Prototypes: If the prototype is just for looks, materials like ABS plastic or acrylic, which are easy to machine and look good, might be better.

2. How the Material Performs

Think about how the material will perform in your prototype. Here are some key factors:

Choosing materials that match your prototype’s needs will help ensure it works well in real life.

3.Ease of Machining and Cost

Not all materials are easy to machine, and this can affect both the quality of your prototype and how much it costs to make.

Ease of Machining: Some materials, like aluminum, are easy to work with and can be cut precisely with a smooth finish. Others, like harder metals or brittle plastics, might be more difficult to machine, which can increase costs and time.

Cost: Materials can vary greatly in price. While metals like titanium offer great performance, they are more expensive than alternatives like aluminum or plastic. Balancing cost with your project’s needs is crucial, especially if you’re on a budget.

4.Surface Finish and Post-Processing

The surface finish is especially important if your prototype needs to look good or fit together with other parts precisely.

Surface Finishing Requirements:  Some materials, such as acrylic or aluminium, can have an appealing surface directly off the CNC machine. Others may require further effort, such as sanding, polishing, or coating, to appear their finest.

Post-processing: Consider how the material will respond to subsequent treatments. Some materials may stretch or weaken during finishing operations, while others may improve with further stages.

5.Environmental Impact and Sustainability

Today, sustainability is more important than ever. When choosing materials, think about their environmental impact.

Recyclability: Using recyclable materials like aluminum and steel can help reduce waste and make your project more eco-friendly.

Material Source: Consider where the materials come from. Are they renewable, or do they require a lot of energy to produce? Choosing sustainable materials can help lower the environmental impact of your project.

6.Availability of Materials

Finally, think about how easy it is to get the materials you want. Some special materials might take longer to source or might not be readily available, which could slow down your project. Choosing materials that are easy to get can help keep your project on track.

Conclusion:

Choosing the right material is an important aspect of successful CNC fast prototyping. You could contribute to your project succeed by making sound choices based on the purpose of your prototype, the material's performance, ease of machining, cost, surface polish, environmental effect, and availability. Whether you're making an actual product or a visual mockup, choosing the correct material helps guarantee that your prototype accomplishes precisely what you want it to do.

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All You Need to Know About Sheet Metal Fabrication with HLH

Modern manufacturing relies largely on sheet metal fabrication, a process that turns plain metal sheets into complex parts and structures used in everything from consumer electronics to aircraft. Leading the industry in sheet metal fabrication, HLH combines modern technology with expert production to provide full solutions for customers.

Everything you need to know about using HLH for sheet metal manufacturing is provided here.

An Overview of Sheet Metal Fabrication:

The method includes bending, cutting, and assembling flat metal sheets into a variety of different parts. These components are necessary for industries like construction, electronics, automotive, and aerospace. Depending on the needs of the application, the manufacturing procedure usually begins with a sheet of metal, which can be aluminum, steel, copper, or another alloy.

The fabrication process includes several steps:

 Sheet Metal Fabrication Process         

Design and Planning:  CAD Modeling, Material Selection         

Cutting: Shearing, Laser Cutting, Plasma Cutting & Waterjet Cutting 

Forming: Bending, Stamping, Rolling, Embossing         

Joining: Welding, Riveting, Adhesive Bonding & Fastening        

Finishing: Deburring, Polishing,Painting or Powder Coating, & Anodizing          

Inspection/Quality Control: Dimensional Inspection, Material Testing, Functional Testing

Assembly: Final Assembly & Functional Testing            

HLH’s Expertise in Sheet Metal Fabrication

HLH has established itself as a trusted manufacturing company for sheet metal fabrication, providing a complete range of services customized for each project. Here's what makes HLH stand out in the industry:

HLH Rapid is a leading company in sheet metal fabrication. The company achieve this by using modern equipment such as high-precision laser cutters and CNC press brakes, which allow them to create complex parts with precise measurements and reliable quality.

HLH Rapid has vast experience with various metals, including copper, stainless steel, aluminium, and speciality alloys, allows them to select the ideal material for any application while keeping cost, weight, and strength in mind.

The company provides flexible manufacturing as well as rapid prototyping, enabling prompt turnarounds and effective large-scale runs while upholding high standards through strict requirements and inspections at every point. We also provide customisable assembly procedures, specialised finishes, and custom tooling, all of which are catered to the particular needs of each client.

Conclusion:

Sheet metal fabrication is a critical process in modern manufacturing, enabling the production of a wide range of components across various industries. We have the capabilities to deliver high-quality, customized solutions that meet your specific needs.

By choosing HLH for your sheet metal fabrication projects, you’re ensuring that you receive precision, reliability, and excellence every step of the way.

If you would like to discuss your requisites, please send us an email at info@hlhrapid.com or upload your CAD file here to get an instant quote.

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CNC Machining vs. Additive Manufacturing: Understanding the Key Differences

In today's manufacturing world, CNC machining and additive manufacturing are two key methods that serve different production needs. Each has its own strengths and weaknesses, so it's important to know how they differ to make the best choices in manufacturing.

This blog explains the main differences between CNC machining and additive manufacturing, focusing on their benefits and uses.

CNC Machining: Precision Through Subtraction

Overview:

CNC machining is a traditional manufacturing method that involves the precise removal of material from a solid block using computer-controlled tools. This subtractive process utilizes rotary cutters, drills, and mills to achieve the desired shape and dimensions.

Materials and Techniques:

CNC machining is compatible with a broad range of materials, including metals (such as aluminum, steel, and titanium), plastics, and composites. The process is renowned for its ability to produce high-precision components with tight tolerances, making it ideal for applications that demand rigorous accuracy, such as aerospace, automotive, and medical industries.

Advantages:

High Precision: CNC machining excels in producing parts with tight tolerances and detailed specifications.

Material Versatility: Capable of working with a variety of materials, including high-strength metals and complex composites.

Consistency: Once set up, CNC machines can produce consistent results across large production runs.

Limitations:

Waste Generation: As a subtractive process, CNC machining can result in significant material waste, impacting overall efficiency and cost.

Setup Time: The initial setup for CNC machining can be time-consuming and costly, particularly for complex or custom parts.

Additive Manufacturing: Innovation Through Addition

Overview:

Additive manufacturing, commonly known as 3D printing, is a cutting-edge technology that builds objects layer by layer from a digital model. This additive process allows for the creation of complex geometries and intricate designs that are challenging to achieve with traditional methods.

Materials and Techniques:

Additive manufacturing supports a diverse range of materials, including thermoplastics, resins, metal powders, and even bio-materials. Technologies such as FDM (Fused Deposition Modeling), SLA (Stereolithography), and SLM (Selective Laser Melting) enable the production of parts with varying degrees of complexity and material properties.

Advantages:

Design Flexibility: Capable of producing highly complex and customized parts with intricate internal structures.

Rapid Prototyping: Ideal for quick prototyping and low-volume production, allowing for rapid iterations and design changes.

Material Efficiency: Minimizes material waste by using only the necessary amount of material to build the part.

Limitations:

Production Speed: Additive manufacturing can be slower for large-scale production compared to traditional methods.

Precision Variability: While precise, the level of detail may vary depending on the technology and material used.

Comparative Analysis

1. Production Process

CNC Machining: Subtractive process that removes material from a solid block to achieve the final shape.

Additive Manufacturing: Additive process that builds up layers of material to form the final part.

2. Material Handling

CNC Machining: Effective with a range of solid materials, including metals and plastics.

Additive Manufacturing: Utilizes a variety of raw materials, including powders and filaments, suitable for complex designs.

3. Precision and Tolerance

CNC Machining: Known for high precision and tight tolerances, suitable for detailed and exact specifications.

Additive Manufacturing: Offers design flexibility with varying precision depending on the technology and material.

4. Production Volume and Speed

CNC Machining: Efficient for medium to high-volume production, though initial setup can be time-consuming.

Additive Manufacturing: Excels in low-volume production and rapid prototyping, but may be less efficient for large-scale manufacturing.

5. Environmental Impact

CNC Machining: Can generate material waste due to the subtractive nature of the process.

Additive Manufacturing: More material-efficient with minimal waste, supporting sustainable manufacturing practices.

CNC machining and additive manufacturing are both useful options for any kind of production demands. CNC machining is still a popular alternative for high-precision, high-volume production, but additive printing offers unique flexibility for complicated and customised items. Understanding these differences allows manufacturers to choose the best technology for a given project, material requirements, and production goals.

In many circumstances, combining the two methods may take use of their individual strengths, delivering a holistic solution to current production difficulties. Businesses may improve their production processes and promote development in their respective industries by carefully evaluating the different features of CNC machining and additive manufacturing. To get an instant quote, upload your file here: https://hlhrapid.com/instant-quote/

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How CNC Machining Supports Customization of Automotive Parts?

In automotive design and manufacturing, customization is very important. Whether you want to improve a car's performance, change its look, or make it stand out, CNC machining is a great method for customizing car parts.

But what is CNC machining, and how does it help with customization? Let’s explain it in simple terms.

What is CNC Machining?

CNC stands for Computer Numerical Control. It’s a technology that uses computers to control machines that cut, shape, and finish materials. In CNC machining, a computer program directs a machine to perform precise cutting tasks on materials like metal, plastic, and wood. This allows for incredibly accurate and complex shapes to be made, which is essential for customizing automotive parts.

Precision and Accuracy

One of the biggest advantages of CNC machining is its precision. When you want to customize a part of your car, such as a new intake manifold or custom wheels, the parts need to fit perfectly. CNC machines can create parts with extremely tight tolerances, meaning the parts will be exactly as designed. This precision ensures that all customized parts fit perfectly and function as intended.

Creating Complex Designs

Cars often need parts with intricate designs. For example, you might want a custom grille or a specialized bracket for a performance upgrade. CNC machining can handle these complex designs with ease. The computer controls allow the machine to make detailed cuts and shapes that would be very difficult or impossible to achieve by hand. This means that custom designs can be brought to life with high accuracy.

Speed and Efficiency

CNC machines are fast. Once a design is programmed into the computer, the machine can produce parts quickly and consistently. This is especially useful when you need multiple parts, such as for a limited edition vehicle or a small batch of custom accessories. CNC machining can produce these parts faster than traditional methods, saving time and making the customization process more efficient.

Flexibility in Design Changes

Sometimes, a design needs to be adjusted or refined. With CNC machining, making changes to a part’s design is relatively easy. Since the design is controlled by a computer program, you can quickly update the program to reflect any changes. This flexibility means you can experiment with different designs and make adjustments without having to start from scratch each time.

High-Quality Finishes

Custom automotive parts often require a high-quality finish to look great and perform well. CNC machining can achieve smooth, precise finishes on a variety of materials. Whether it’s a custom aluminum wheel or a carbon fiber component, CNC machines can provide the surface quality needed for both functional and aesthetic purposes. This ensures that custom parts not only fit well but also look polished and professional.

Cost-Effective Customization

Although CNC machining may seem expensive at first, it can be cost-effective in the long run. For custom parts, the cost of setting up the machine and programming can be offset by the precision and efficiency of the machining process. Additionally, CNC machining reduces waste material, which helps keep costs down. For custom parts that need to be produced in small quantities, CNC machining can be a cost-effective solution.

Supporting Innovation

The automotive industry is constantly evolving, with new technologies and designs emerging all the time. CNC machining supports innovation by allowing designers and engineers to create and test new ideas quickly. Whether it’s a new engine component, a unique body part, or an innovative accessory, CNC machining provides the flexibility and precision needed to explore and implement new concepts.

In Summary

CNC machining is really important for customizing car parts. It's precise, can handle complex designs, works quickly, and is flexible, making it perfect for creating custom parts. Whether you want to boost your car's performance or change its look, CNC machining can help make your ideas a reality with accuracy and speed. Knowing how to use CNC machining can help you get the best results when customizing your car.

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What Is CNC Prototype Machining and When To Use It?

When you need to order detailed and functional prototypes for a product or part, CNC prototype machining is a tried-and-true process that may suit your project perfectly. In this article, we will take a deeper look into the CNC prototype machining process, its advantages and applications, how it compares to other rapid prototyping technologies, and how to progress from CNC prototypes to full-fledged CNC production.

What is CNC Prototype Machining

CNC prototype machining is a subtractive manufacturing process whereby physical prototypes or products models are made using computer numerical control (CNC) machines. These machines are programmed to precisely and automatically shape and cut materials, such as metal and plastics based on digital design specifications. This is known as a subtractive process, meaning the prototype is made by cutting material away.

CNC machines work based on a pre-uploaded file called a CAD file, which only the computer can read. In other words, there is close to no human involvement in the production process. This makes CNC prototype machining one of the most reliable ways to make prototypes due to its speed and incomparable accuracy that allows engineers and designers to test and validate their designs before moving on to full-scale production.

Advantages of CNC Prototype Machining

As you may or may not already know, you have many options when it comes to manufacturing prototypes. Why use CNC for prototypes? In answer, here are 5 advantages that make CNC prototype machining so attractive among product engineers and designers.

1. Yields Fast Turnaround Time

CNC machining offers rapid prototyping, which means that prototypes can be created relatively quickly compared to traditional machining methods. This allows for faster design iterations and a shorter time to market.

2. Highly Repeatable

Since CNC machines are operated by a computer, it produce prototypes with a high degree of consistency. This repeatability ensures that multiple prototypes will be virtually identical, making it easier to evaluate and refine the design.

3. Very Precise

Another reason that CNC is so popular for prototypes is how it produces precise prototypes with high tolerance specifications. This means that the prototype can be extremely detailed – almost to the point that it is just as (or nearly) detailed as the final end use part.

4. Available in a Wide Range of Materials

With CNC prototype machining, you’re not limited to certain types of material. Your parts can be machined from a wide range of plastics as well as metals, including copper, aluminium, and stainless steel. This flexibility in material choice allows designers to experiment with different materials to find the most suitable one for their final product.

5. Suitable for Complex Geometry

CNC machines excel at creating prototypes with intricate and complex designs. They can handle three-dimensional shapes and intricate details with ease, which is especially valuable for industries like aerospace, automotive, and medical devices.

When To Use CNC Prototype Machining (+ Applications)

CNC prototype machining is a versatile and valuable tool in various industries for creating prototypes and models. It is typically used when:

Testing New Product Designs: CNC prototype machining is ideal for testing and validating new product designs. It allows designers and engineers to create physical models quickly and accurately to assess not just the appearance but also form, fit and function.

Iterative Development: When a design needs multiple iterations and refinements, CNC machining can produce prototypes rapidly, facilitating the testing and refinement process.

Material Evaluation: It is used to test and evaluate different materials to determine their suitability for a particular application. This is valuable for selecting the best materials for the final product.

Low-Volume Production: For low-volume production runs, CNC prototype machining is cost-effective and efficient, offering a viable alternative to traditional manufacturing methods.

Applications of CNC prototype machining are widespread and include:

Medical: It goes without saying that the medical industry needs tools and equipment that are as precise and flawless as possible. Lives literally depend on their proper function. CNC machining offers the accuracy needed to properly demonstrate how new innovations will work in this field via prototypes.

Automotive: CNC prototype machining can help automotive companies test parts that will contribute to the functionality (and more importantly, the safety) of new vehicles.

Aerospace: Just as in automotive, precision is key in the aerospace industry. One small deviation or flaw could cause ripple effects that compromise entire aircraft, making it dangerous for them to be used. CNC machining is accurate enough that aerospace engineers rely on it to make manifolds, parts for landing gear, and other essential aircraft components.

Consumer Electronics: Prototyping for gadgets, mobile devices, and other consumer electronics to test their functionality and aesthetics.

Oil & Gas: CNC machines are often responsible for producing parts for the oil and gas industry, including drill bits, spacers, hydraulics, and more. You’ll also find CNC prototype machining used in the military industry, and to produce electronics.

CNC Prototype Machining Vs 3D Printing

When thinking of prototyping technologies, you will often across different methods CNC machining and 3D printing. CNC prototype machining and 3D printing are two distinct but complementary technologies in the realm of rapid prototyping and product development.

3D printing is additive, meaning it produces prototypes or parts by printing them layer by layer. Meanwhile, CNC machining is subtractive. Essentially, it carves the prototype out of raw material by removing sections of the material that don’t fit with the desired design.

Because 3D printing is an additive process, it allows for the creation of more intricate and complex geometries that would otherwise be challenging or impossible to achieve through traditional subtractive methods. For this reason, it also allows for minimal material waste, as it only uses the exact amount of material required for the model.

In contrast, due to its subtractive nature, CNC prototype machining is ideal for achieving extremely precise and accurate prototypes that often cannot be achieved with 3D printing technologies.

Selecting between 3D printing and CNC machining hinges on the project’s unique demands. 3D printing shines when swift creation of intricate designs is essential, while CNC machining stands out for its unrivaled precision and robustness, particularly in conventional or material-intensive applications. Frequently, engineers and designers synergize these two technologies to craft diverse components, enabling a comprehensive optimization of their prototypes.

From CNC Prototypes To CNC Production

One of the biggest benefit of using CNC prototype machining is the pipeline to production. In most cases, prototypes are produced close to the end of the ideation phase, right before mass production of the final product begins. CNC machining can produce highly accurate prototypes that are just as functional as the end use part. They can even be made of the same materials.

This means that once the prototype has been approved, it is a simple matter to go straight into production of the end use part. Thus, the pipeline from CNC prototype to CNC production is natural and quick.

Now that you’re confident in the knowledge of how CNC prototype machining works and when it’s best used, we encourage you to contact an expert at HLH Rapid and get a quote on your next prototyping project.

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Most Popular Tooling Materials in Injection Moulding and Their Typical Tool Life

When it comes to injection moulding, the mould tool is the most critical and costly component in the process. There are many tooling material options to choose from: aluminium, soft and semi-hardened steel, and hardened steel. While mould makers like HLH can assist you in choosing a suitable tooling material for your project, it’s worth gaining a basic foundation and understanding your options to avoid costly errors, waste, and defects down the road.

In this article, we will look at the most popular steel and aluminium tooling options available for plastic injection moulding, their typical tool life, the pros and cons of each, and scenarios in which each is best to use.

Popular Tooling Material Options for Injection Moulding

Aluminium

S50C

P20

NAK80

H12

S136

1. Aluminium

Aluminium (AL) is often used as a quick and lower-cost alternative to steel tooling. AL has good machinability and excellent heat transfer properties (cools quickly and efficiently), which makes it a good option for prototyping and low-volume production runs. A main drawback is that the tooling life is generally shorter, and not all grades of plastics are suited for aluminium tooling; for instance, materials that require high mould temperatures.

Soft tooling option.

Commonly used for prototype and low-volume tooling — with an average life of 10,000 shots depending on the grade and part complexity.

Easy to machine and offers excellent turnaround times.

Less durable than steel tooling and not suited to plastics that require high mould temperatures like polyetherimide (PEI), polyether ether ketone (PEEK) or polysulfone (PSU).

2. S50C

S50C is a ‘soft’ steel option that is especially popular in China for prototype tooling. It is a great for general applications and a good alternative to aluminium. However, if the part material or surface finish calls for a hardier tool, P20 steel is used.

Soft steel.

Commonly used for rapid tooling tooling applications — with an average life of 50,000 shots or less depending on the grade and part complexity.

Less expensive than P20 steel.

Less durable than P20 and not suitable for materials with abrasive additives.

Pro Tip: You can often get Chinese tools like S50C and P20 at the price of an aluminium tool. Most Chinese tool shops prefer working with steel tools for rapid tooling because they are harder, more robust, and easier to weld.

3. P20

P20 is a ‘soft’ steel often used as a standard steel tooling option and is the first choice for materials without abrasive additives. For prototype or development tooling, P20 steel offers several advantages over aluminium: it is stronger, more durable and offers a longer tool life; it is less costly; and it is generally more resistant to scratching than aluminium. A main drawback is that P20 is not very resistant to erosion or chemical corrosion, which can impact its tool life.

Soft steel.

Commonly used for prototype tooling and intermediate quantities — with an average life of 50,000 cycles or more, depending on the part’s geometry and tolerances.

P20 is harder and more durable than aluminium, with approximately a 5x longer tooling life.

May require coatings or surface treatment to protect against corrosion and erosion.

P20 Application Case Study: HLH Rapid Uses P20 Steel Tool For SOL Reader’s E-Ink Glasses.

 4. NAK80

NAK80 is a semi-hardened tool steel typically used for more demanding applications. NAK80 is typically used for higher quality parts and transparent and high-gloss components. It also works better with resins with glass fibers or hard, engineering-grade plastics like Delrin or Aceral (POM). Although it’s more corrosion resistant than P20, one key drawback is that it takes longer to machine.

Hardened steel.

Commonly used for bridge tooling and production tooling — with a typical tool life of 300,000 to 500,000 shots.

NAK80 takes polishing well, and produces optically clear and high glossy parts.

Costs more than P20 steel tool and typically takes 20-25% longer to produce.

5. H13

H13 is a ‘strong’ steel that is robust and have exceptional resistant to heat. It is most commonly used for high production quantity tooling and to address wear when running abrasive materials. H13 also works well for materials that require high tool temperatures like polyamide-imide (PAI), PEEK, and liquid crystal polymer (LCP).

Strong steel.

Commonly used for high volume runs of several hundred thousand to 1 million cycles.

H13 is best for aggressive resins and optical parts made of clear plastic like acrylic (PMMA) or polycarbonate (PC).

More expensive than P20 and NAK80 steel.

6. S136

S136 is stainless steel that offers excellent hardness and is mainly used for speciality cases in high production tooling. It has good corrosion resistance, which makes it good for corrosive environments or materials such as polyvinyl chloride (PVC) and polypropylene (PP). It also has excellent polishability and is a good choice for large-size precision parts. The main drawback is that S136 costs the most and has the lowest thermal efficiency, so unless you require a high production run, it may not financially make sense.

Hard stainless steel.

Commonly used for high volume runs of 1 million or more.

S136 is best for corrosive plastic materials like PVC and PP.

Most expensive steel tooling option among the five options.

Other Tooling Material Options

Above, we’ve listed the 5 most commonly used aluminium and steel tooling material options for injection moulding projects, however, there are many other tool material options for special cases and applications. Check them out in the list below.

A2 tool steel

718

718H

738

738H

S7

S50C

SS420

STAVAX 48-52HRC

SKD61

1.2083

1.2343

1.2344

1.2738H

2083H

2083 HRC48-52

2344 (HRC48-52)

2738

Custom tooling & injection moulding

Submit CAD, get a quote within 24-48 hours or less

Get a quote now

The Typical Tooling Game Plan at HLH

Typically, our clients begin with single-cavity S50C or P20 steel tools for prototyping and developmental applications—S50C for our rapid tools and P20 if the part material or surface finish calls for a hardier tool. For applications requiring engineer-grade or glass fibre resins, or for moulds necessitating a higher level of polishing, NAK80 steel is preferred.

Often, for niche market or specialized products, P20 or NAK80 steels may be all the client needs to satisfy demand. These steels require a lower investment than full production tooling, helping customers minimize costs in the early stages and get initial products to market faster.

If the product demand is high and where it makes sense, customers may move on to H13 or other hardened steel, production multi-cavity tooling.

Fast Tooling & Injection Moulding With HLH Rapid

At HLH, we make prototype tooling, bridge tooling and production tooling in-house for simple to complex injection moulding projects. If you are unsure what tooling material to go for, get in touch with our engineering team at info@hlhrapid.com.

To get started on your next injection moulding project, simply submit your 3D CAD along with any project details like material, surface finish or quantity, to our contact form. Our team will get back with a quote within 24 to 48 hours or less.

Visit our website: https://hlhrapid.com/blog/injection-mould-tooling-material-steel-and-aluminium-tools/

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The Benefits of Using Carbon Steel in CNC Machining: A Technical Perspective

CNC machining is currently the most widely used in modern manufacturing, making it possible to create detailed and accurate parts. Carbon steel is one of the popular materials used in this process because of its great properties and flexibility. In this blog post, we will look at the technical advantages of using carbon steel in CNC machining and why many industries prefer it.

Here are the highlights of using Carbon Steel in CNC Machining:

Mechanical Properties and Strength

Carbon steel is well-known for its great mechanical properties, making it perfect for CNC machining. Its high tensile strength means parts can handle a lot of stress and load without bending or breaking. This strength is especially important in industries like automotive and aerospace, where parts face heavy forces.

        Yield Strength and Hardness

Low Carbon Steel (up to 0.3% carbon): This steel is moderately strong and easy to machine, making it good for parts like brackets and fasteners that don't need high hardness.

Medium Carbon Steel (0.3% to 0.6% carbon): This type of steel balances strength and flexibility. It's often used for gears, axles, and other parts that need more hardness than low carbon steel.

High Carbon Steel (0.6% to 1.0% carbon): This steel is very hard and resistant to wear, making it ideal for cutting tools and dies.

Machinability and Precision

The machinability of a material is a critical factor in CNC machining. Carbon steel exhibits excellent machinability, which allows for the efficient and precise manufacturing of complex parts. This property is influenced by the carbon content and the presence of other alloying elements.

Cutting Speeds and Feed Rates

Optimal Cutting Conditions: Carbon steel can be machined at high cutting speeds and feed rates, which enhances productivity. For example, low carbon steel can be machined at cutting speeds up to 300 feet per minute (fpm), while high carbon steel may require slower speeds around 150 fpm to prevent tool wear.

Tool Life: The material's machinability helps extend the life of cutting tools by reducing wear and tear, which is critical for maintaining tight tolerances and surface finishes.

Heat Treatment and Customizability

One of the standout features of carbon steel is its ability to undergo various heat treatment processes to alter its mechanical properties. Heat treatment techniques such as quenching, tempering, and annealing can significantly enhance the hardness, strength, and toughness of carbon steel parts.

Heat Treatment Processes

Quenching and Tempering: Increases hardness and strength by rapidly cooling the material after heating, followed by reheating to a specific temperature to achieve the desired toughness.

Annealing: Softens the material, improving its machinability and making it easier to form and cut.

These processes let you adjust carbon steel’s properties to fit different needs, making it a flexible material for CNC machining.

 Cost-Effectiveness and Availability

Carbon steel is easy to find and cheaper than metals like stainless steel or titanium. Its low cost makes it a good choice for manufacturers who want to balance performance and budget. Because it’s widely available, there’s always a steady supply, which helps reduce lead times and supports large-scale production.

Material Grades and Standards

-ASTM Standards: Carbon steel grades are standardized by organizations such as ASTM (American Society for Testing and Materials), ensuring consistent quality and properties across different batches.

-Cost-Effective Production: The lower cost of carbon steel raw materials contributes to the overall cost-effectiveness of CNC machined parts.

Corrosion Resistance

Carbon steel doesn’t resist corrosion on its own, but coatings and finishes can make it more durable. Techniques like galvanizing, powder coating, and painting create a protective layer that stops rust and corrosion.

Protective Coatings

Galvanizing: Involves applying a zinc coating to the steel, offering excellent corrosion resistance and extending the lifespan of the parts.

Powder Coating: Provides a durable, aesthetically pleasing finish that also improves corrosion resistance.

In conclusion, carbon steel is great for CNC machining and is widely used in many industries. Its strong mechanical properties, easy machinability, customizability with heat treatment, cost-effectiveness, and potential for better corrosion resistance make it popular in automotive, aerospace, and construction.

Using carbon steel, manufacturers can create high-quality, reliable, and affordable parts that meet modern engineering and manufacturing needs. If you would like to discuss more about Carbon Steel using CNC Machining, feel free to reach us at info@hlhrapid.com our submit your CAD file here to get an Instant Quote.

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Top Reasons to Use CNC for Rapid Prototyping in various industries

Modern product development places great emphasis on rapid prototyping, allowing industries to innovate, make adjustments, and expedite the process of bringing products to market. CNC machining is widely preferred for this purpose and is highly suitable for rapid prototyping across different industries.

1.Aerospace Industry

Precision and Accuracy:

In the aerospace sector, precision is critical, and CNC machines are important in guaranteeing that each prototype satisfies particular specifications. For parts to be produced that can resist high stress levels and difficult climatic conditions, accuracy is crucial.

Complex Shapes:

Many parts for aircraft are made with complicated patterns and complex forms. Prototypes that nearly match the finished product may be produced because to CNC machines' ability to manage these  complexity with ease.

2.Automotive Industry

Speed and Efficiency:

The rapid pace of innovation is essential in the automotive industry. High-quality prototypes can be quickly produced using CNC machining, reducing the time required to go from concept to physical model. Engineers can efficiently test and enhance designs due to this speedy turnaround.

Material Variety:

CNC machines can handle a variety of materials, including metals and polymers, which are commonly used in car components. This versatility makes it easier to create realistic prototypes that closely resemble the finished product.

3.Medical Devices

Smooth Finishes:

Medical instruments require smooth, high-quality surfaces for safety and operation. Because it produces excellent finishes, CNC machining is suitable for developing medical device prototypes that fulfil high criteria.

Easy Changes:

Developing medical devices often involves many design changes. CNC machining allows for quick and easy modifications, speeding up improvements and refinements.

4.Consumer Electronics

Complex Designs:

Consumer electronics often have compact and intricate designs. CNC machines excel at creating detailed prototypes with precise shapes, ensuring that every component fits perfectly.

Scalability:

Once a prototype is finalized, CNC machining can easily produce multiple units with consistent quality. This scalability is great for electronics companies moving from prototypes to small-scale production.

5.Architecture and Construction

Material Flexibility:

CNC machines can work with a variety of materials like wood, plastics, and composites. This flexibility is useful in architecture and construction, where prototypes might involve different materials to accurately represent the final structure.

Cost-Effective:

CNC machining cuts down the need for expensive molds and tools, making it a cost-effective choice for creating architectural models and construction prototypes.

6.Fashion and Jewelry

Detailed Designs:

In fashion and jewelry, intricate designs and fine details are essential. CNC machining provides the precision needed to create detailed prototypes of jewelry pieces and fashion accessories.

High-Quality Finishes:

High-quality finishes are crucial in these industries. CNC machining ensures that prototypes not only look professional but also meet the high standards expected by consumers.

CNC machining offers many benefits for rapid prototyping in various industries. From the precision needed in aerospace and medical devices to the speed and efficiency required in automotive and consumer electronics, CNC technology is a versatile and reliable solution. Its ability to handle complex designs, work with different materials, and produce high-quality finishes makes it an invaluable tool in the prototyping process. By using CNC machining, companies can streamline product development, innovate faster, and bring new products to market more efficiently.

If you would like to discuss your requisites with our experts, submit your CAD files here or send us an email at info@hlhrapid.com

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How to Design Ribs for Plastic Parts: Injection Moulding Design Guide

Ribs are thin support features frequently found in plastic injection moulded part designs. They are often used strategically to replace thick wall sections to avoid sink marks, warp, and voids, and help improve overall part function. In some cases, ribs also act as decorative features.

To fully benefit from the capabilities of rib features, it is important that your injection mould model is designed according to a number of recommendations. This article covers the scenarios in which ribs should be used in injection moulding and offers a comprehensive guide to the best design practices for rib features.

When to incorporate rib features in your design

We’ve listed several scenarios below in which rib features work particularly well for:

Plastic parts that require maximum strength without increased wall thickness

Plastic parts that are subject to pressure, torsion and bending

Plastic parts that are complex and large

Plastic parts needing extra strength without increasing overall weight or material usage

Rib Design Guidelines

Rib Height

Rib height should not exceed 3 times the nominal wall thickness. Ribs that are too long will increase the difficulty of injection moulding, causing problems like voids and sink marks. Ideally, you want to keep ribs as short as possible while still being functional.

Rib Thickness

As a general rule of thumb, ribs should not be thicker than 60% of the nominal wall thickness. Maintaining an appropriate rib-to-wall ratio is essential to prevent issues such as air bubbles, shrinkage patterns and stress concentration. Ultimately, avoid thick ribs whenever possible.

Rib Radii

The base of a rib should always be rounded with a radius to prevent an area of concentrated stress in the part. This radius should typically be 0.5 to 1 times the thickness of the part wall to increase rib strength.

Rib Spacing

When incorporating multiple ribs, it’s recommended to space them out at least 2 to 3 times the nominal wall thickness. It’s essential to leave adequate space, as ribs placed too close together can create cooling issues, which can increase cycle times and sink risk.

Rib Draft

A draft angle of at least 0.5 degrees on each side should be incorporated to allow for easy part ejection from the mould. Only crush ribs should be made without a draft angle.

Summary of Rib Design Guidelines

Injection moulding rib design best practices

Incorporating ribs is a critical feature that should be carefully considered for nearly all enclosures, housings, casings and other plastic parts where wall thickness is important. In order to ensure successful moulding of rib designs, it is important to closely follow best design practices.

Avoid Excessive Ribbing: Overloading a design with excessive ribs can significantly prolong cycle times, heighten ejection risks, and increase material usage. Instead, focus on strategic placement of ribs only where necessary to provide the required structural support while minimising these drawbacks.

Ensure Adequate Vents: It it essential properly vent around ribs in injection-moulded parts, as improper vent will cause excessive injection pressure, short shots, burn marks, sink and splay.

Maintain Uniform Wall Thickness: Variations in wall thickness can lead to uneven cooling rates, warping, and dimensional inaccuracies. Maintaining uniform wall thickness is crucial to enhance mould filling, minimize cycle times, and improve overall part quality and appearance.

Avoid Abrupt Transitions From Thin to Thick: Sudden changes in thickness from thin to thick sections can result in uneven filling, increased shrinkage, and potential defects such as sink marks or warping. Gradual transitions help promote uniform material flow and reduce stress concentrations.

Follow Rib Design Guidelines: Considering factors like rib height, length, placement, and orientation helps optimize part design for efficient moulding and superior mechanical properties.

Injection moulding & DFM feedback with HLH Rapid

Use the Rib Design Guidelines above to help design your parts for manufacturing then export your 3D CAD files in an STEP format. Submit your drawings to our site contact form and our engineering team will get back with a quote and comprehensive DFM (design for manufacturing) feedback.

Visit our website to Learn More: https://hlhrapid.com/knowledge/rib-design-guide-injection-moulding/

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Understanding the Manufacturing Steps for CNC Machining Parts

A variety of parts and components may be produced using the flexible and accurate CNC machining method. It includes removing material from a workpiece and shaping it into the required form using computer-controlled machinery. Numerous sectors, including aerospace, automotive, medical, and electronics, employ this technique extensively. Let's examine the main production processes that go into creating CNC-machined items in order to better grasp how CNC machining operates.

Step 1: Design and CAD Modeling

The design of the item or component is the initial stage in the CNC machining process. CAD (Computer-Aided Design) software is used by designers and engineers to produce intricate 3D models of the component. This model functions as a machining process plan. With the use of CAD software, exact specifications, measurements, and tolerances can be set, guaranteeing that the finished product satisfies all necessary requirements.

Step 2: Converting CAD to CAM

After CAD modelling is finished, it must be translated into a format that the CNC machine can read. Computer-Aided Manufacturing, or CAM, software is used for this. The toolpath, or collection of instructions that tells the CNC machine how to move and cut the material, is created by CAM software. The toolpath contains details on feed rates, cutting speeds, and other parameters in addition to the type of tool that will be utilised.

Step 3: Material Selection

One of the most important aspects of CNC machining is selecting the appropriate material. In addition to being compatible with the machining process, the material must be appropriate for the intended use. Metals like steel, titanium, and aluminium, as well as polymers like ABS, nylon, and PEEK, are frequently utilised in CNC machining. Composites are also frequently utilised. Strongness, longevity, weight, and cost are among the considerations that go into choosing a material.

Step 4: Setting Up the CNC Machine

Before machining can begin, the CNC machine needs to be set up. This involves installing the appropriate cutting tools and securing the workpiece in place. The machine operator ensures that the workpiece is properly aligned and that the cutting tools are correctly positioned. Calibration is also performed to ensure that the machine's movements are accurate and precise.

Step 5: Programming the CNC Machine

With the machine set up, the next step is to program it using the toolpath generated by the CAM software. The program is loaded into the CNC machine's controller, which interprets the instructions and executes the machining process. The operator may perform a dry run or simulation to verify that the program is correct and to identify any potential issues before actual machining begins.

Step 6: Machining the Part

The machining process has different steps to create specific shapes and sizes. Common CNC machining operations include:

Milling: A rotating cutting tool removes material to make flat surfaces, slots, and pockets.

Turning: The workpiece spins while a cutting tool shapes it into cylinders.

Drilling: A rotating drill bit makes holes in the workpiece.

Tapping: Threads are cut into pre-drilled holes for screws.

Grinding: A grinding wheel smooths the surface for fine finishes and tight tolerances.

During machining, the CNC machine follows the programmed toolpath, precisely removing material to create the desired part. The process is highly automated, allowing for consistent and repeatable results.

Step 7: Quality Control and Inspection

The part is subjected to stringent quality control and inspection following machining to make sure it satisfies the necessary tolerances and requirements. Numerous measurement instruments and methods are employed, including optical inspection systems, coordinate measuring machines (CMM), micrometres, and callipers. Before the part moves on to the following step, any deviations or flaws are found and fixed.

Step 8: Post-Processing

Post-processing procedures could be required, depending on the specifications of the component. These procedures can involve heat treatment (increasing material qualities), deburring (removing burrs and sharp edges), polishing (getting a smooth surface finish), and coating or painting (improving appearance and protection). Making ensuring the part is prepared for its intended application is the goal of post-processing.

Step 9: Assembly and Integration

The CNC-machined part might need to be merged with other parts if it's a part of a bigger assembly. This entails positioning, fitting, and fastening the component. Depending on the complexity and volume of manufacturing, assembly can be completed manually or with the aid of automated equipment.

Step 10: Final Inspection and Testing

The completed product goes through one more round of testing and inspection before being dispatched to the customer. This guarantees that the component satisfies all functional and performance specifications. Depending on the part's intended use, testing may involve stress, load, functional, and environmental tests. The component is cleared for shipping after passing every test.

Conclusion

Each step is critical to ensuring that the final product meets the required specifications and standards. By understanding the manufacturing steps involved in CNC machining, Manufacturers can produce high-quality parts and components with precision and efficiency. Whether for prototyping or mass production, CNC machining continues to be a vital technology in modern manufacturing.

Do you want to start your next CNC project with us? Upload your file here and get an Instant Quote in minutes! For more information, send us an email at info@hlhrapid.com

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How Does the Plastic Molding Process Work?

Plastic molding is a popular and versatile way to create many everyday plastic items. It has changed how we make everything from basic toys and bottle caps to advanced car parts and medical tools. In this blog post, we'll look at the various techniques, steps, and applications of plastic molding.

What is Plastic Molding?

Plastic moulding is the technique of shaping plastic material into the required forms with the use of a mould. The process that yields the final form involves melting plastic resin and then pumping or squeezing it into a mould cavity. It's where the resin cools and solidifies. The primary goal of plastic moulding is the production of trustworthy, intricately detailed items with precise specifications.

Types of Plastic Molding

There are several plastic molding techniques, each with its unique advantages and applications. Some of the most common methods include:

1. Injection Molding:

Injection molding is one of the most widely used plastic molding techniques. In this process, plastic pellets are melted and injected into a mold cavity under high pressure. The molten plastic fills the mold, takes its shape, and cools down to form a solid part. Injection molding is ideal for producing high-volume, high-precision parts with complex geometries.

2. Blow Molding:

   Blow molding is used to create hollow plastic objects such as bottles, containers, and automotive fuel tanks. The process involves heating a plastic tube (parison) and inflating it within a mold cavity using compressed air. As the plastic expands, it conforms to the shape of the mold, creating a hollow part.

3. Compression Molding:

Compression molding involves placing a preheated plastic material into an open mold cavity. The mold is then closed, and pressure is applied to shape the plastic. This method is commonly used for creating large, intricate parts and is well-suited for thermosetting plastics.

4. Rotational Molding:

Rotational molding, or rotomolding, is used to produce large, hollow parts such as tanks, containers, and playground equipment. In this process, a powdered plastic material is placed in a mold, which is then heated and rotated around multiple axes. The plastic melts and coats the interior of the mold, forming a hollow part as it cools.

5. Extrusion Molding:

Extrusion molding is a continuous process used to create long, linear plastic products such as pipes, tubing, and sheets. In this method, plastic pellets are melted and forced through a die, which shapes the material into the desired profile. The extruded plastic is then cooled and cut to the required length.

The Plastic Molding Process

While each plastic molding technique has its unique steps and equipment, the general process can be broken down into several stages:

1. Material Selection:

The first step in the plastic molding process is selecting the appropriate plastic material. The choice of material depends on factors such as the desired properties of the final product, the intended application, and cost considerations. Common materials used in plastic molding include polyethylene, polypropylene, polystyrene, and polyvinyl chloride (PVC).

2. Mold Design and Fabrication:

Once the material is chosen, the next step is designing and fabricating the mold. The mold is typically made from steel or aluminum and consists of two halves: the cavity (female) and the core (male). The mold design must account for factors such as part geometry, draft angles, and cooling channels to ensure proper part ejection and dimensional accuracy.

3. Material Melting:

In the injection molding process, plastic pellets are fed into a hopper and then transferred to a heated barrel, where they are melted. The molten plastic is then pushed through a nozzle into the mold cavity by a reciprocating screw or plunger. In other molding methods, such as compression molding, the plastic material is preheated before being placed in the mold.

4. Injection or Compression:

For injection molding, the molten plastic is injected into the mold cavity under high pressure, ensuring it fills the entire cavity and takes the shape of the mold. In compression molding, the preheated plastic material is placed in the open mold, which is then closed and subjected to pressure to shape the plastic.

5. Cooling and Solidification:

Once the plastic fills the mold cavity, it begins to cool and solidify. Proper cooling is crucial to prevent defects such as warping, sink marks, and internal stresses. Cooling channels within the mold help regulate the cooling process and ensure uniform temperature distribution

6. Part Ejection

After the plastic has solidified, the mold opens, and the finished part is ejected. Ejection mechanisms such as ejector pins or plates are used to push the part out of the mold without causing damage. The mold is then ready for the next cycle.

7. Finishing and Quality Control:

The final step involves trimming any excess material (flash) from the part and performing quality control checks to ensure the part meets specifications. This may include inspecting for defects, measuring dimensions, and conducting functional test.

Applications of Plastic Molding

Plastic molding is used in a wide range of industries and applications due to its flexibility and cost-effectiveness. Some common applications include:

Automotive:

Dashboard components, bumpers, and interior trim.

- Packaging:Bottles, containers, and caps.

- Consumer Goods:Toys, household items, and electronics enclosures.

- Medical Devices: Syringes, IV components, and diagnostic equipment.

- Construction:Pipes, fittings, and insulation materials.

The plastic molding process is a cornerstone of modern manufacturing, enabling the production of high-quality, cost-effective plastic parts for a wide range of applications. By understanding the different molding techniques, stages of the process, and key considerations, manufacturers can optimize their operations and deliver superior products to the market.

Whether it's injection molding, blow molding, compression molding, rotational molding, or extrusion molding, each method offers unique advantages that contribute to the ever-evolving world of plastic manufacturing.

Who we are?

HLH is a distinctive blend of Western and Eastern expertise, founded by industry veteran Vader Yu from China and Director James Murphy from the UK. We support innovative companies worldwide, leveraging our skills and experience to quickly manufacture high-quality prototypes and production parts. If you would like to get an instant quote, submit your CAD file here.

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What you need to know about Low-Volume Injection Molding?

Injection molding is a popular method for making large quantities of identical plastic parts. For small batches or custom parts, low-volume injection molding (LVIM) is ideal. This guide covers everything about LVIM, including its benefits, uses, process, and important tips.

Here’s what you need to know about Low-Volume Injection Molding?

Low-volume injection molding involves producing smaller quantities of parts, typically ranging from a few hundred to several thousand units. Unlike high-volume injection molding, which is ideal for mass production, LVIM is suited for prototyping, pilot runs, and short production runs. This approach allows manufacturers to create high-quality, precision parts without the high costs and long lead times associated with large-scale production.

Benefits of Low-Volume Injection Molding

1. Cost-Effective Tooling

One of the most significant advantages of LVIM is the reduced cost of tooling. Traditional high-volume injection molding requires expensive, hardened steel molds that can withstand millions of cycles. In contrast, LVIM often utilizes softer aluminum molds, which are more affordable and quicker to produce. This cost reduction makes LVIM accessible for smaller businesses and startups.

2. Faster Turnaround Time

LVIM offers a quicker turnaround time compared to high-volume production. The use of aluminum molds and the focus on smaller batches mean that molds can be designed, produced, and tested in a fraction of the time it takes for traditional molds. This speed is crucial for businesses looking to bring new products to market quickly or make rapid design iterations.

3. Flexibility and Customization

Low-volume injection molding provides greater flexibility in terms of design changes and customization. Since the molds are less expensive and easier to modify, manufacturers can quickly adapt to design changes without significant financial implications. This flexibility is particularly beneficial during the prototyping phase or when producing customized parts for specific applications.

4. High-Quality Parts

Despite the lower costs and quicker turnaround times, LVIM does not compromise on quality. Modern low-volume injection molding processes utilize advanced technologies and materials to ensure that the final parts meet the same high standards as those produced through high-volume molding. This means you can expect precision, consistency, and durability in your parts.

 Applications of Low-Volume Injection Molding

LVIM is suitable for a wide range of applications across various industries. Some common use cases include:

 1. Prototyping

For companies developing new products, LVIM allows them to produce prototype parts that can be tested and refined before committing to large-scale production. This helps identify and address design flaws early in the development process.

 2. Custom and Niche Products

Businesses producing custom or niche products often have limited production runs. LVIM provides a cost-effective solution for creating high-quality parts without the need for large quantities.

3. Market Testing

Before launching a new product, companies can use LVIM to produce small batches for market testing. This approach allows for gathering customer feedback and making necessary adjustments without the risk of large-scale production.

4. Bridge Production

LVIM serves as an excellent bridge production method. When transitioning from prototyping to full-scale production, LVIM can fill the gap, ensuring that there are no interruptions in the supply chain.

The Low-Volume Injection Molding Process

1. Design and Prototyping

The first step in the LVIM process is designing the part and creating a prototype. This stage involves using CAD software to develop a detailed design, which is then used to create a prototype. Rapid prototyping techniques such as 3D printing can be employed to produce the initial prototype for testing and validation.

2. Mold Creation

Once the design is finalized, the next step is creating the mold. For LVIM, molds are typically made from aluminum due to its cost-effectiveness and ease of machining. The mold is designed based on the CAD model and produced using CNC machining or EDM (electrical discharge machining) processes.

3. Injection Molding

With the mold ready, the injection molding process begins. The chosen plastic material is melted and injected into the mold cavity under high pressure. After the material cools and solidifies, the mold is opened, and the part is ejected. This process is repeated to produce the required number of parts.

4. Quality Control

Quality control is a critical step in the LVIM process. Each part is inspected for defects, dimensional accuracy, and overall quality. Advanced inspection techniques, such as CMM (coordinate measuring machine) or optical scanning, can be used to ensure that the parts meet the required specifications.

5. Finishing and Assembly

After quality control, the parts may undergo additional finishing processes, such as trimming, painting, or coating. If the parts are part of a larger assembly, they are then assembled and prepared for shipment.

Here are the few key considerations for Low-Volume Injection Molding

1. Material Selection

Choosing the right material is crucial for the success of LVIM. Factors to consider include the part's intended use, mechanical properties, environmental conditions, and cost. Common materials used in LVIM include ABS, polycarbonate, nylon, and polypropylene.

2. Mold Design

The mold design significantly impacts the quality and efficiency of the injection molding process. Considerations include the number of cavities, gate design, cooling channels, and ejection mechanisms. Working with an experienced mold designer can help optimize the mold for better performance and longevity.

3. Production Volume

Understanding the intended production volume helps determine the most cost-effective and efficient approach. For very low volumes, alternative methods like 3D printing or CNC machining might be more suitable. LVIM is ideal for quantities in the range of hundreds to thousands of parts.

4. Lead Time

While LVIM offers faster turnaround times compared to high-volume production, it's essential to account for lead times in the planning process. Factors such as mold creation, material availability, and production scheduling can impact the overall timeline.

Check out your Sample Guide for the Injection Molding:

Important: Values are for your reference only. You can submit your CAD file in our web form to provide you with real time information.

Conclusion

Low-volume injection molding is a great manufacturing method for making small to medium quantities of products. It's cost-effective, flexible, and produces high-quality items. Whether you're a startup creating a new product prototype or a business needing custom parts, LVIM offers an ideal mix of affordability and quality. By learning about the process and its benefits, you can use LVIM to get your products to market quickly and efficiently.

Visit our website to learn more about Low Volume Injection Moulding and get a quote within 24 hours. www.hlhrapid.com

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What Commonly Used Injection Molding Materials Have: An Insight into Their Properties and Applications.

Injection molding is a widely utilized manufacturing process that involves injecting molten material into a mold to create a wide array of products. The choice of material is crucial as it influences the properties, cost, and applications of the final product.

Here, we delve into some of the most used injection molding materials, exploring their characteristics and common applications.

1. Polypropylene (PP)

Characteristics:

Polypropylene is a type of plastic that is very versatile. It is lightweight, resists chemicals well, and can handle repeated stress without breaking. This makes it perfect for uses that need to be durable.

Applications:

PP is often used in packaging, car parts, everyday products, and medical devices. Repeated bending makes it great for items like living hinges that need to bend a lot.

 2.Acrylonitrile Butadiene Styrene (ABS)

Characteristics:

ABS is a type of plastic made by mixing styrene and acrylonitrile with polybutadiene. This makes it very strong, tough, and keeps its shape well.

Applications:

ABS is commonly used in car parts, electronic cases, everyday items, and toys. Its strength and easy shaping also make it popular for 3D printing.

3. Polyethylene (PE)

Characteristics:

Polyethylene comes in different types like HDPE and LDPE. It resists chemicals, insulates electricity, and is flexible. HDPE is harder and more rigid, while LDPE is softer, more flexible, and melts at a lower temperature.

Applications:

PE is used for many items like containers, bottles, plastic bags, and toys. It is also great for medical and food packaging because it is safe and non-reactive.

4. Polycarbonate (PC)

Characteristics:

Polycarbonate is a strong type of plastic known for being tough and clear. It can be shaped easily and is used in many ways.

Applications:

Polycarbonate is often used in eyeglass lenses, medical tools, car parts, and electronics. Its clearness and strength make it perfect for things that need to be strong and easy to see through.

5. Polystyrene (PS)

Characteristics:

Polystyrene is a type of man-made plastic that comes in two types: solid and foam. It is light, stiff, and cheap to make.

Applications:

PS is used in things like disposable utensils, plastic models, CD cases, and foam packaging. The foam kind, called expanded polystyrene (EPS), is common in insulation and packing materials.

6. Nylon (Polyamide - PA)

Characteristics:

Nylon is a man-made material that is strong and flexible. It can handle being pulled hard, resist wear and tear, and is good with heat and chemicals.

Applications:

Nylon is used in cars, machines, everyday items, and clothes. It is tough and strong, perfect for parts that get a lot of use and pressure.

7.Polyethylene Terephthalate (PET)

Characteristics:

PET is a thermoplastic polymer resin of the polyester family. It is known for its strength, thermostability, and resistance to moisture.

Applications:

PET is widely used in beverage bottles, food packaging, and synthetic fibers. Its recyclability makes it a popular choice for environmentally conscious manufacturers.

Different materials used in injection molding have special qualities that suit various needs. For example, polypropylene is versatile and tough, while polycarbonate is strong and clear. Knowing these traits helps manufacturers pick the best material for their specific use, ensuring good performance, cost-efficiency, and eco-friendliness. As technology and materials improve, more options for injection molding become available, opening new possibilities for innovation in manufacturing.

There are 7 Most Common Injection Moulding Gate Types - Choosing a Gate for Your Project

An injection molding gate is a specially designed opening that controls how molten plastic flows into the mold. Its main job is to manage the amount and direction of the plastic as it fills the mold. There are different kinds of gates, such as edge gates, sub gates, and direct sprue gates, each with its own unique features and uses. We will look at these types more closely below.

Most common types of injection moulding gate:

Edge Gates

Tunnel / Submarine (Sub) Gates

Cashew Gates

Sprue or Direct Gates

Fan Gates

Diaphragm Gates

Pin Gates

Inject moulding is a prototyping tool made by HLH Rapid. Before beginning production, our engineers choose the ideal gate for your design and build bespoke moulds and parts based on your CAD drawings. Simply use our site contact form to send us your CAD designs and project specifics, including quantity, material, and any surface finishing. In a span of 24 to 48 hours, our staff will furnish an estimate.

Do you want to learn about Injection Molding or need a Free Quote? Submit your CAD drawings and project details, including quantity, material, and surface finish, through our site contact form. Our team will send you a quote within 24-48 hours.