plastic mold makers

Chinese Injection Molding Companies

The Rise of Chinese Injection Molding Companies: A Cost-effective and Technologically Advanced Solution

Introduction: Injection molding is a widely used manufacturing process that involves injecting molten material into a mold to create various products. In recent years, Chinese injection molding companies have emerged as dominant players in the industry, offering cost-effective solutions and advanced technology. This article explores the advantages of choosing Chinese injection molding companies, considerations when selecting them, showcases top companies, presents successful case studies, and provides valuable tips for engaging with these companies.

Overview of Chinese Injection Molding Industry: The Chinese injection molding industry has experienced remarkable growth and development over the years. Factors such as a large labor force, favorable government policies, and a robust manufacturing infrastructure have contributed to China’s dominance in this sector. With a focus on continuous improvement, Chinese companies have invested heavily in research and development, leading to technological advancements that rival global competitors.

Advantages of Choosing Chinese Injection Molding Companies:

Cost-effectiveness: Chinese injection molding companies offer competitive pricing due to lower labor costs and economies of scale. This cost advantage makes them an attractive choice for businesses looking to optimize their manufacturing budgets.
Technological Advancement: Chinese companies have embraced cutting-edge machinery and equipment, allowing them to produce high-quality products with precision. Additionally, they boast a skilled workforce that is trained in the latest manufacturing techniques, ensuring superior results.
Wide Range of Capabilities: Chinese injection molding companies have the capability to work with diverse materials and cater to a wide range of product types. Their expertise in customization enables businesses to create unique and tailored solutions for their specific needs.

Considerations when Selecting Chinese Injection Molding Companies:

Quality Assurance: It is crucial to ensure that the chosen Chinese company maintains high-quality standards. Look for certifications and adherence to industry standards, as well as robust quality control processes to guarantee the final product’s integrity.
Communication and Language Barriers: Overcoming language barriers can be a challenge when working with Chinese companies. However, effective communication channels, such as employing bilingual staff or utilizing translation services, can bridge this gap and ensure smooth collaboration.

Top Chinese Injection Molding Companies: A. Company A: With a solid reputation in the industry, Company A offers a comprehensive range of injection molding services. Their core competencies include precision molding, rapid prototyping, and efficient project management. Testimonials from satisfied clients highlight their commitment to quality and timely delivery.

B. Company B: Known for their technological prowess, Company B excels in complex injection molding projects. Their expertise lies in multi-material molding, tooling design, and value-added services. Positive feedback from clients underscores their professionalism and ability to exceed expectations.

Case Studies: Successful Projects with Chinese Injection Molding Companies: A. Project A: In the automotive industry, a client faced challenges in producing intricate components. The Chinese company provided innovative solutions using advanced molding techniques, resulting in cost savings and improved product performance. The client’s satisfaction with the final outcome showcased the capabilities of Chinese injection molding companies.

B. Project B: A client in the consumer electronics sector required high-quality, customized parts. The Chinese company’s expertise in material selection and precision molding ensured the successful completion of the project, meeting the client’s specifications and achieving exceptional product quality.

Tips for Engaging with Chinese Injection Molding Companies:

Conduct thorough research: Before partnering with a Chinese injection molding company, conduct extensive research on their reputation, capabilities, and track record. This will help ensure a reliable and trustworthy collaboration.
Request samples and prototypes: To assess the company’s capabilities and product quality, request samples or prototypes before committing to a large-scale project. This step allows you to verify their expertise and alignment with your requirements.
Establish clear communication channels: Effective communication is key to a successful partnership. Clearly define communication channels and expectations to avoid misunderstandings and facilitate smooth information exchange.
Visit the facilities: If feasible, consider visiting the Chinese company’s facilities to gain firsthand insights into their manufacturing processes, quality control measures, and overall working environment. This visit will foster trust and enhance the relationship.

At Sincere Tech Plastic Mold company, we are committed to staying at the forefront of the industry and embracing future trends and innovations. We constantly explore advanced materials and composites that offer enhanced performance and sustainability. Our continuous investment in research and development enables us to offer cutting-edge solutions that meet the evolving needs of our customers. We are one of the best mould suppliers in China.

Furthermore, we are dedicated to environmentally friendly practices. We actively seek out sustainable alternatives, such as biodegradable polymers and recycling initiatives, to minimize the environmental impact of our manufacturing processes. By choosing our custom injection molding services, you can align your brand with sustainable manufacturing practices and contribute to a greener future.

Quality is our utmost priority, and we adhere to stringent quality control measures throughout the entire manufacturing process. Our state-of-the-art facilities and skilled technicians ensure that each product undergoes rigorous inspection and testing, guaranteeing exceptional performance, reliability, and customer satisfaction.

Partner with Sincere Tech China mold maker for your custom injection molding needs, and experience the highest level of professionalism, expertise, and innovation. We are dedicated to helping you bring your ideas to life, delivering superior products that excel in performance, durability, and cost-effectiveness.

Contact us today to discuss your project requirements and discover how our polypropylene injection molding services can elevate your manufacturing processes to new heights. Together, let’s unlock the full potential of polypropylene and create exceptional products that shape the world around us.

Conclusion: Chinese injection molding companies have emerged as cost-effective and technologically advanced solutions for businesses worldwide. Their ability to offer competitive pricing, advanced technology, and a wide range of capabilities make them an attractive choice. By considering the advantages, conducting thorough research, and establishing effective communication, businesses can confidently engage with Chinese injection molding companies, tapping into their expertise and achieving outstanding results. The future prospects of this industry look promising, with continuous growth and innovation on the horizon.

can silicone be injection molded

Can Silicone Be Injection Molded? Exploring the Possibilities

Introduction: Silicone is a versatile material known for its flexibility, durability, and heat resistance. Injection molding, on the other hand, is a widely used manufacturing process for producing high-quality and precise parts. But can silicone be injection molded? In this article, we will delve into the intricacies of silicone injection molding, its challenges, advancements, and applications.

What is Injection Molding? Injection molding is a highly efficient technique used to create intricate and complex parts with precision. It involves injecting molten material into a mold cavity under high pressure. The material then cools and solidifies, resulting in a finished product. This process offers several advantages, including high production rates, cost-effectiveness, and design flexibility.

Can Silicone Be Injection Molded? Silicone, a synthetic polymer, can indeed be injection molded. However, it presents unique challenges compared to other materials. Silicone has a low viscosity, which makes it difficult to control during the injection process. Additionally, its high thermal conductivity requires precise temperature control to avoid inconsistencies in the final product. Despite these challenges, advancements in silicone injection molding technology have made it a viable option for various applications.

Silicone Injection Molding Process: To successfully injection mold silicone, specific considerations must be taken into account. The process begins with preparing the silicone material, which is typically in the form of a two-part liquid compound. The injection molding machine is then set up to accommodate the unique properties of silicone, such as temperature control and specialized injection nozzles. The injection process involves injecting the molten silicone into the mold cavity, followed by cooling and solidification. Finally, the molded part is ejected from the mold.

Benefits and Applications of Silicone Injection Molding: Silicone injection molding offers numerous benefits. Its inherent flexibility allows for intricate designs and complex geometries. The material’s resistance to extreme temperatures, chemicals, and UV radiation makes it ideal for demanding applications. Silicone injection molded parts also exhibit excellent durability, electrical insulation properties, and biocompatibility. As a result, silicone injection molding finds applications in various industries, including medical devices, automotive components, consumer products, and industrial equipment.

At Sincere Tech, we are dedicated to maintaining our position as a leading plastic mold company by embracing industry advancements and anticipating future trends. We actively explore innovative materials and composites that offer improved performance and sustainability. Through ongoing investments in research and development, we deliver cutting-edge solutions that address the evolving needs of our customers. As one of the best injection mold suppliers in China, we pride ourselves on our commitment to excellence.

In line with our commitment to sustainability, we prioritize environmentally friendly practices. We proactively seek sustainable alternatives, such as biodegradable polymers, and implement recycling initiatives to minimize the environmental impact of our manufacturing processes. By choosing our custom injection molding services, you can align your brand with sustainable manufacturing practices and contribute to a greener future.

Quality is of the utmost importance to us, and we maintain stringent quality control measures throughout the entire manufacturing process. Our state-of-the-art facilities and skilled technicians ensure that each product undergoes rigorous inspection and testing, guaranteeing exceptional performance, reliability, and customer satisfaction.

When you partner with Sincere Tech as your preferred China mold maker, you can expect the highest level of professionalism, expertise, and innovation. We are dedicated to helping you bring your ideas to life, delivering superior products that excel in performance, durability, and cost-effectiveness.

Our expanded capabilities include:

Rapid Prototyping: We offer rapid prototyping services to quickly transform your concepts into tangible prototypes, allowing for iterative design improvements and accelerated product development.
Precision Tooling: Our advanced tooling capabilities enable us to create high-quality molds with tight tolerances, ensuring consistency and precision in your injection-molded products.
Overmolding: We specialize in overmolding, which allows for the combination of multiple materials or components, resulting in enhanced functionality, aesthetics, and durability.
Insert Molding: Our expertise in insert molding enables us to securely encapsulate inserts within the molded parts, facilitating efficient assembly and enhancing product performance.
Two-Shot Molding: With two-shot molding, we can produce complex, multi-material components in a single operation, reducing assembly requirements and enhancing design possibilities.
Value-Added Services: In addition to injection molding, we offer a range of value-added services, including product assembly, packaging, and logistics support, streamlining your supply chain and reducing costs.

Partner with Sincere Tech Mould suppliers for your custom injection molding needs, and benefit from our comprehensive capabilities, unwavering commitment to quality and sustainability, and our drive to exceed your expectations at every step of the process. Together, let’s bring your innovative ideas to life.

Conclusion: In conclusion, silicone can indeed be injection molded, albeit with unique challenges. However, advancements in silicone injection molding technology have made it a viable option for producing high-quality, precise parts. The benefits of silicone injection molding, such as flexibility, durability, and resistance to extreme conditions, make it an attractive choice for various industries. When considering manufacturing methods for silicone products, it is crucial to evaluate the specific requirements and consult with experienced professionals. With its immense potential and continued advancements, silicone injection molding is poised to play a significant role in the future of manufacturing.

Aluminum casting service

Aluminum casting services have become increasingly popular in recent years due to its lightweight and durable properties. Aluminum is an ideal material for a wide range of applications, from automotive parts to consumer goods. In this article, we will explore the various aspects of aluminum casting services, including its types, applications, processes, and quality control measures.

Aluminum casting services refer to the process of creating aluminum parts using a mold. This process involves melting aluminum metal, pouring it into a mold, and allowing it to solidify. Once solidified, the part is removed from the mold and can be further processed, such as machining or painting.

Aluminum casting services have become increasingly popular due to its lightweight and durable properties. It is an ideal material for a wide range of applications, from automotive parts to consumer goods. Aluminum is also recyclable, which makes it an environmentally friendly option for manufacturers.

Understanding Aluminum Casting

Aluminum casting is a process of creating aluminum parts using a mold. The process involves several steps, including:

Melting the aluminum metal: The first step in aluminum casting is to melt the aluminum metal. This is typically done in a furnace, where the metal is heated to its melting point.
Pouring the metal into the mold: Once the metal is melted, it is poured into the mold. The mold is typically made of sand, which is then removed once the part has solidified.
Allowing the part to solidify: Once the metal is poured into the mold, it is allowed to solidify. This process typically takes a few minutes to an hour, depending on the size of the part.
Removing the part from the mold: Once the part has solidified, it is removed from the mold. The mold is then cleaned and prepared for the next casting.

Types of Aluminum Castings

There are several types of aluminum castings available, including:

Ingot casting: Ingot casting involves pouring molten aluminum into a mold and allowing it to solidify. This process is typically used for large quantities of aluminum parts.
Sand casting: Sand casting involves creating a mold using sand. The molten aluminum is poured into the mold, and the sand is then removed. This process is typically used for smaller quantities of aluminum parts.
Investment casting: Investment casting involves creating a mold by pouring a liquid material, such as plastic or resin, into a cavity. The molten aluminum is then poured into the mold, and the liquid material is removed. This process is typically used for creating complex and intricate aluminum parts.

Aluminum Casting Applications

Aluminum casting services are used in a wide range of industries, including:

Automotive: Aluminum casting is widely used in the automotive industry for creating parts such as engine blocks, wheels, and suspension components.
Aerospace: Aluminum casting is used in the aerospace industry for creating parts such as airframes, engine components, and landing gear.
Construction: Aluminum casting is used in the construction industry for creating parts such as windows, doors, and railings.
Consumer goods: Aluminum casting is used in the consumer goods industry for creating products such as food and beverage containers, electronics, and sporting goods.

Aluminum Casting Processes

There are several aluminum casting processes available, including:

Gravity casting: Gravity casting involves pouring molten aluminum into a mold that is open at the top. The mold is then tilted, allowing the aluminum to flow into the mold.
Pressure die casting: Pressure die casting involves injecting molten aluminum into a mold under high pressure. This process is typically used for creating large quantities of aluminum parts with high precision.
Centrifugal casting: Centrifugal casting involves pouring molten aluminum into a spinning mold. This process is typically used for creating large, complex parts with a single piece of metal.

Quality Control in Aluminum Casting

Quality control is crucial in aluminum casting to ensure that the final product meets the desired specifications. This process involves several steps, including:

Inspection: All parts are inspected for defects, such as porosity, shrinkage, and cracks.
Testing: Parts are tested to ensure that they meet the required strength, hardness, and other properties.
Validation: Validation is performed to ensure that the process is repeatable and that the final product meets the desired specifications.

Aluminum Casting Services

Aluminum casting services are provided by a variety of companies, including foundries and engineering firms. These services typically include:

Design: Companies that provide aluminum casting services can help design the part using computer-aided design (CAD) software.
Engineering: Companies that provide aluminum casting services can provide engineering support, including analysis and simulation of the part.
Prototyping: Companies that provide aluminum casting services can create prototypes of the part to test and validate the design.
Production: Companies that provide aluminum casting services can produce large quantities of the part using various casting processes.

Welcome to GC Precision Mould, your premier China die casting manufacturer and China Mold Maker. We specialize in producing high-quality plastic molds, die casting molds, and a wide range of die cast parts from materials such as aluminum, zinc, and magnesium.

At GC Precision Mould, we are dedicated to providing our clients with the best possible aluminum die casting and other casting products and services. Our team of experienced engineers and technicians use the latest technology and techniques to ensure that every part we produce meets the highest standards of quality and accuracy.

Our products are widely used in a variety of industries, including automotive, consumer electronics, medical, and industrial equipment. We work closely with our clients to understand their specific needs and develop custom solutions that meet their unique requirements.

Whether you need a single plastic mold or a complete die casting production line, we have the expertise and resources to deliver exceptional results. Contact us today to learn more about our services and how we can help you achieve your manufacturing goals.

If you have a project that needs Die casting China for your die casting project or mould suppliers to make injection molding products, contact us to get the best price now.

Conclusion

Aluminum casting services are a crucial part of many industries, including automotive, aerospace, construction, and consumer goods. The various types of aluminum casting, such as ingot casting, sand casting, and investment casting, offer different advantages and disadvantages. Quality control measures, such as inspection, testing, and validation, are essential to ensure that the final product meets the desired specifications. With the right aluminum casting services provider, companies can create high-quality aluminum parts that meet their needs.

10 Tips for Polypropylene PP Injection MOLDING

Polypropylene continues to gain popularity in the injection mold industry. With a low-density consistency and chemical resistant design, it is often used to produce items such as medical devices and automotive parts. While polypropylene resins offer a number of benefits, it is important to monitor the temperature threshold during the smelting and printing process. Here are the top 10 tips for injection molding polypropylene resins.

1) Make sure you have the right molding equipment

The road to successful injection moulding starts with the right molding equipment. Fortunately, polypropylene can be printed accurately using unchanged one-stage thread molding equipment.

2) Consider pre-drying ONLY if you use certain polypropylene resins

“In most plastic processing factories, resin dryers are standard equipment. An important exception to this is facilities that exclusively process polyolefins such as polyethylene and polypropylene. These are some polymer families which do not require drying because this material family is not hygroscopic. “

Unlike most commercial polymers that are highly polar, polypropylene is a non-polar substance, allowing you to pass the pre-drying process. The only resin that may require pre-drying is some filled polypropylene resin. This advantage allows you to save time during the injection moulding process.

3) Use a melting temperature range of 400 ° F to 500 ° F

Using melting temperatures higher than 500 ° F can cause flashing, warpage, shrinking and burning. Temperatures lower than 400 ° F, on the other hand, can produce poor quality flow and surface markings. When you set your melting temperature, try to reach a melting temperature that is 25-50 ° F higher than the minimum filling temperature.

4) Strives for an injection pressure range of 800 to 1,500 psi

Injection pressure is another variable that can help control common injection moulding problems with polypropylene molding. While the injection pressure you set must reflect the construction and size of the item. In general, the pressure should be able to fill about 99% of the parts to prevent problems with flashing and stickiness.

5) Don’t rush the injection process

Be prepared for the injection process to consume the majority of each whole cycle. While injection time does not significantly affect the warpage, patience with the injection process is important because the accurate injection is a major factor in controlling shrinkage.

6) Choose a mold temperature around 50-150 ° F

The mold temperature must be carefully regulated to reduce stress and surface imperfections. A mold temperature of 50-150 ° F helps prevent this trap. In addition, ensure that the mold is uniformly cooled to facilitate the removal of components from the mold.

7) Never rush time

Hold time plays an important role in preventing warpage and shrinkage. Therefore resist the urge to remove parts of the mold before it is cool enough. Allowing the part to cool to around 130 ° F is recommended to produce satisfactory results.

8) Use minimal back pressure to increase your cycle time

The ideal backpressure for polypropylene injection mold is usually between 50 and 100 psi. Backpressure in this range can help increase your cycle time. Exceptions to this rule of thumb are cases that require mixing pigments.

9) Adjust your mold or polypropylene level if sticking occurs

Sticking is not common with polypropylene because it has exceptional release properties. However, if minor adhesions occur, you can easily improve the attachment by making minor changes to the mold or using a grade of polypropylene that has been lubricated internally.

10) Seek support from trained industry professionals

The only best way to ensure your satisfaction with polypropylene resin injection molds is to seek guidance from a leader in the injection mold industry. We invite you to contact us for further injection mold tips. With almost years of industry experience, we have the resources and expertise to help you develop the unlimited injection moulding process. We look forward to hearing from you!

midplane models

1. Our midplane models are very accurate with best mesh quality. Usually the quality of our midplanes is much better than most fusion models made automatically by Moldflow.

2. The size of midplane is far less than of fusion models with the same level of details. But in most cases midplane is more detailed model.

3. It is possible to have 3 rows or more of elements on most ribs (it is the minimal requirements for warpage analysis) but keep the very reasonable size of the model. Usually we can see only two or even one rows of elements on ribs in case of automatically created fusion models. It is not good for the flow analysis and definitely bad for warpage analysis.

4. Using midplane model it is more easy to check different thicknesses of ribs in case of problem with filling or warpage.

5. Using midplane model it possible to fully control the thicknesses distribution also in cases difficult for fusion analysis. For example we can accurate represent places on the model at spasmodic change of thickness on a small interval. Such places very important for good analysis but very difficult for fusion models. Usually fusion models gives you very rough results in such cases.

6. For thin-walled parts midplane model are better because fusion model is too rough in thickness’s calculation.

7. The calculation of midplane models is faster. This is important for complex models and in cases of multiple calculations with the aim to find a best solution.

Plastic Moling Company

GC Tech Plastic Molding Company has developed a wide variety of auxiliary equipment to enhance the part quality or meet the customer’s requirement. 1st Tech offers a complete line of secondary operations including:

Heat Transfer Decals
Hot/Foil Stamping
Color Appearance Matching
Assembly
Specialized Packaging
Bar Coding
JIT/Kanban Delivery Systems

GC Tech Plastic Molding Company was founded in November of 2005 in DongGuan China to provide fully integrated thermoplastic injection molding services including industrial and mechanical design, prototyping, mold fabrication, high capacity molding, plastic mold, part decorating, secondary operations, the assembly including electronic and mechanical subassemblies and fulfillment. GC Plastic Molding Company is a customer-driven organization that enables customers to bring high-quality products to market faster and at reduces costs by combining a multi-disciplinary team of highly skilled professionals with technologically advanced equipment.

GC mold is dedicated to developing and manufacturing quality, China plastic products, and services which consistently exceed customer’s expectations and span from concept to design to product fulfillment.

With experience in a variety of custom molded products and a specialization in high tech products, our commitment to quality, communication, schedule and lowest cost of design makes 1st Tech the right choice for your project no matter what the volume.

Molding Corporation offers:

Innovative Product Design Assistance
In-house Tool Design, Build & Maintenance
Rapid Tooling and Prototyping
Competitive Pricing
On-time Delivery
Superior Customer Service

Currently,GC Plastic injection Mold Company has fifteen (15) molding machines ranging from 15 ton to 650 ton with auxiliary equipment and is expanding to 36,000 sq. ft. Operations are running 7 days a week, 24 hours a day. The equipment is state-of-the-art Computer Aided Design stations, computer controlled tooling equipment and computer controlled molding equipment which allows for computer generated modeling of a design from concept to production to prove a design prior to fabrication.

Stereolithography

Stereolithography is also known as 3D Layering and 3D Printing. Stereolithography is the process of turning CAD designs into real 3D objects in a matter of hours.

In the past, it could take days, weeks, or even months to prototype a part using conventional methods. The design would have to be done, then the tooling on the molds would need to be finished. Stereolithography goes straight from design to the prototype.

Stereolithography is a manufacturing process that uses a UV laser to create successive cross-sections of a 3D object within a vat of liquid photopolymer. A platform is placed on top of the vat filled with the polymer (an epoxy resin). Before the build begins, the platform is moved to a point just below the surface of the resin. As the solid state UV laser traces the layer in the polymer, the resin begins to cure; solidifying the part to be manufactured.

Stereolithography Machine

There are 4 main parts of the Stereolithography Machine:

Liquid Photopolymer Tank: holds serveral gallons fo the clear, liquid plastic.
Perforated Platform: the platform is immersed in the tank and can be moved up and down as the process is performed.
Ultraviolet Laser: transorms the liquid polymer into the 3D object.
Computer: controls the laser and movement of the platform during the printing process.

The photopolymer is sensitive to ultraviolet light, so when the laser passes through the polymer it hardens into each layer of the 3D object.

Stereolithography Process

The Stereolithography process is basically performed in the following way:

Create a 3D model with CAD software.
Stereolithography software slices up CAD model into many layers; about 5-10 per millimeter.
3D printer (Stereolithography machine) “
The platform drops down into the tank layer by layer until the model is completed.

Stereolithography is not a quick process. It can take few minutes per layer depending on the size and number of objects being created. Typically it can take anywhere from 6-12 hours to complete one run.

After designing your 3D object in the CAD software, it need to be modified to add supports to raise it off of the platform slightly. The SLA machine will render your object unattended. Once it is done, the platform is raised out of the polymer and your 3D models are rinsed in a solvent and baked in an ulta-violet oven to completely cure the plastic.

What can you make with stereolithography?

If you can design it with CAD, you can most likely produce it with stereolithography. You may need to add internal bracing to the 3D object so it will not collapse during the printing or curing processes. Once your object is made, you can actually test it out in an application, such as parts that fit on a motor or other machine. Of course, these parts won’t be used on a real machine, but they can accurately display if the parts will fit or not.

Stereolithography Costs

Stereolithography is not cheap. The photopolymer plastic can cost hundreds of dollars per gallon. The SLA machines themselves cost hundreds of thousands of dollars. The machines have to be vented because of the fumes the polymers and solvents create. For these reasons you will usually only find stereolithography machines in large companies.

Some companies do offer SLA services at hourly rates though. This allows smaller companies to take advantage of the great benefits of steolithography without having to purchase such expensive equipment.

These high costs are greatly offset by the turn-around time of making prototypes. Stereolithography is considerably faster than machining the test parts, and in today’s world, time is money.

Patented Gearing Technology

Palo Alto, CA—Ikona Gear International, Inc., headquartered in Coqutilam, British Columbia (Canada), has integrated its patented gear designs with high-temperature plastics to develop gears of plastic molded parts for engines and winches. Described in a recent analysis entitled, “Advances in High Temperature Resistant Plastics for Use in Motors & Gears,” the innovation was recognized by Frost & Sullivan as the winner of the 2005 Technology Innovation Award.

Ikona Gear received the award in July at Frost & Sullivan’s Excellence in Emerging Technologies Banquet, an annual event held in Boston to honor companies for pioneering the development and introduction of innovative technologies into their markets. The event recognizes the overall technical excellence of a company and its commitment towards technology innovation.

Ikona needed to design the tooth form in order for its gearing technology to qualify as a new invention. Because of a very high contact ratio and no tip interference, the Ikona gear teeth pair is reported to have zero backlash. Although most of Ikona’s earlier testing was done with standard stock metal, several partners—such as Aircast and Magna International—proposed the fashioning of gear assemblies from plastics. While most of this interest was driven by cost considerations, the Ikona gear profile is said to uniquely solve problems introduced by the characteristics of plastics.

“The Ikona gear design is more rigid, has a much higher contact ratio than standard planetary gear designs, and has lower friction as the gear rolls through its contact range rather than sliding with friction,” said Michael Valenti, research analyst for Frost & Sullivan. “This solves some of the problems with plastics being used in gearing.”

Ikona recently announced a development agreement to provide StarRotor Corporation, Houston, with its patented plsatic molded gear technology for third-generation StarRotor engines. According to the agreement, Ikona will incorporate its gear into the main drive mechanism of the StarRotor engine.

“This project will demonstrate the progression of technology from metal gears to high temperature plastic gears,” notes Valenti. “Ikona hopes to show that it provides a combination of the highest efficiency, compactness, strength, and the best sealing method of transferring energy from StarRotor’s engine into its main gear drive.”

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The Ikona applications will have to be further refined into a high-temperature plastic solution that can eliminate the need to introduce tolerances for metal expansion. Nevertheless, the company has already developed bold new gearing designs that will drive the use of high-temperature plastics.

This report includes information from wire reports.

Flat Grinding Work

Oak Creek, WI—Columbia Grinding has kept a steady eye on the future while working to establish its reputation as “Flat Work Specialists™. Over the years, the Oak Creek, Wis., job shop has consistently expanded its repertoire of grinding, lapping, and honing services. Today, Columbia Grinding applies its services to a long list of products, including stampings, machine parts, and molded foundry products, such as powdered metal parts. The company works with an equally wide array of materials that include basic metals, high alloys, and plastics, molded plastic parts etc.

After adding flat honing/grinding technology to its production operations in April, Columbia Grinding is now able to provide ultra-flat finished surfaces on metals, alloys, and other materials. The firm’s newest capabilities augment an already extensive offering of Blanchard, surface, and double disc grinding services.

“We cover a large spectrum, from large roughing jobs with relatively open tolerances to very fine finishing of small parts,” says Richard J. Lussier, president. “On our new Flat Honing/Fine Grinding machine, we can hold +/- 1 micron on a given load of parts and hold flatness across a part of 1 light band (one eleven millionth of an inch). Depending on the material, when asked to, we can generally hold a 4Ra [surface finish].”

The majority of the company’s equipment is dedicated to flat work jobs. Columbia’s seven Blanchard grinders are used for “the rough and big projects,” Lussier says, while four surface grinders are dedicated to tool room work and production jobs. For high-volume work, the company counts on its seven double disc grinders, which cover the three basic styles of double disc grinding: feed-through, reciprocating, and rotary carrier. The firm’s lapping department comprises six machines: three single-sided, two double-sided, and a 705 Stahli two-sided Flat Honing/Fine Grinding machine, the firm’s newest.

“Most of our work is 2^nd or 3^rd tier, but we do deal with some OEMs directly,” Lussier discloses. “We do work for a lot of different industries, from automotive to agricultural to the medical field. We do a lot of work for machine manufacturers. We even do work in the area of consumer products.”

Although technology plays a huge role in the company’s day-to-day operations, Lussier knows that there’s more to a company’s success than the depth of its equipment list. He credits Columbia’s attainment of ISO 9001:2000 certification as a key to much of the company’s growth and innovation.

“As we grew, we found that to sustain that growth, we not only needed new machines and processes, but also needed a management system to aid in that growth,” he commented. “Our ISO program gave us that management system. We have found that ISO provides the basics that allow our personnel the opportunity to be innovative. Today, you will find a machine on our floor that holds [a tolerance of] +/- 1 micron because of that system.”

Lussier told of an instance when a customer was line boring 5 small connecting rods at a time. The first operation after forging and heat treating, he said, was to grind the faces.

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“We were double disc grinding to flatness tolerance of 0.001-inch, which we were holding with no problem,” he recalled. “The customer would then line bore these parts. They then did a 100% inspection of this operation. They would reject 5-15%, most of which dealt with the line-up of the two bores.

“Through discussions with the customer, we offered a different process of double-sided lapping. We did an experiment and were able to hold a flatness of 0.000011-inch. The most striking benefit was the parallelism control; we were able to hold 0.000020-inch. This allowed them to clamp these parts with no distortion and, thus, the line bore issue was put to rest.”