5-Axis CNC Machined Mold Parts in P20 Steel

Product Specification

1. Design Review and Feasibility Analysis

(1)Design Submission: The client provides the complete mold design, including 3D CAD models of the mold inserts and the final product. Technical drawings specify materials, hardness, and any specific surface finishes or textures.

(2)Mold DFM Analysis: The manufacturing team conducts a critical Design for Manufacturability (DFM) review tailored for molds. They analyze complex geometries, deep cavities, parting lines, draft angles, and any features that may be difficult to machine. They work with the client to optimize the design to ensure it can be machined efficiently and accurately while also facilitating a smooth molding process.

2. Material Selection and Sourcing

(1)Specialized Materials: Based on the final product's material and the required production volume, the team recommends and sources the appropriate mold steel. Common choices include P20 for general-purpose molds, H13 for high-temperature and wear-resistant applications, and NAK80 for a superior finish.

(2)Certification: The raw material is sourced from certified suppliers, and a material test report is obtained to confirm its chemical composition and properties.

3. 5-axis CAM Programming and Tooling Strategy

(1)Advanced Programming: Expert engineers use powerful CAM software to create a highly optimized 5-axis toolpath. This process is crucial for mold making, as it defines how the cutting tool will move along complex, organic surfaces to create the final shape.

(2)Tooling Strategy: A detailed tooling strategy is developed, selecting a variety of cutters—from large roughing tools to tiny ball-end mills for fine detail and finishing—to efficiently and precisely machine all areas of the mold.

4. High-Precision Machining

(1) Seamless Machining: The raw mold steel is loaded into the 5-axis CNC machine. The machine's simultaneous movement on multiple axes allows it to machine complex 3D contours and deep cavities in a single setup. This "one-and-done" approach eliminates the need for manual re-clamping, drastically reducing the risk of error and ensuring exceptional accuracy.

(2) Reduced Finishing: By using the 5-axis machine's full capability, the process can produce an extremely smooth and clean surface, which significantly reduces the amount of time and effort required for post-machining manual polishing.

5. Post-Machining Treatment

(1) Heat Treatment: Mold inserts often undergo heat treatment to achieve the final desired hardness, which is critical for their durability and lifespan.

(2) EDM (Electrical Discharge Machining): For parts with sharp internal corners or very deep, difficult-to-reach features, EDM is used to precisely burn away material, a task that a milling cutter cannot accomplish.

(3) Texturing: If the final product requires a specific surface texture (e.g., a matte finish, a leather-like grain), the mold surface is textured using methods like chemical etching or laser texturing.

6. Final Inspection and Verification

(1) 3D Scanning: The finished mold insert is placed on a Coordinate Measuring Machine (CMM). This advanced equipment performs a comprehensive 3D scan, comparing every point of the physical mold to the original CAD model to verify that all complex surfaces and critical dimensions are within tolerance.

(2) Visual Check: The mold's surface is visually inspected to ensure it meets the client's quality standards for finish and texture.

7. Assembly and Delivery

(1) Final Assembly: The machined components of the mold are carefully assembled.

(2) Secure Packaging: The finished mold is packaged in protective material and a sturdy container to prevent any damage during transit. It's then shipped to the client, ready to begin the injection molding or casting process.

Common Materials in Producing for OEM 5-axis CNC Machined Parts in Mold Making

1. Mold Steels

Mold steels are the most common choice due to their exceptional hardness, durability, and ability to be heat-treated to achieve specific properties.

P20: This is the most widely used mold steel. It comes in a pre-hardened condition, meaning it can be machined directly without requiring a final heat treatment.

Properties: Good machinability, excellent polishability, and adequate toughness.

Application: Ideal for mid-volume production of plastic injection molds and die-casting dies. It is a cost-effective choice for general-purpose applications.

H13: A chromium-molybdenum hot-work steel with high toughness and excellent resistance to thermal fatigue.

Properties: Can withstand high temperatures, has superior wear resistance, and maintains its hardness well.

Application: The go-to material for high-volume plastic injection molds and especially for die-casting molds that handle molten metals like aluminum, as it can endure repeated cycles of heating and cooling.

NAK80: A premium-grade, pre-hardened steel known for its superior machinability and polishability.

Properties: Exceptional machinability, excellent mirror-like finish capability, and good dimensional stability.

Application: Used for molds that require a high-gloss or mirror finish on the final molded part, such as for consumer electronics or optical components.

S7: A shock-resistant tool steel.

Properties: High impact resistance and great shock toughness.

Application: Used for molds with thin walls, delicate features, or those that will be used in applications with high-impact or shock loads.

2. Aluminum Alloys

While not as durable as steel, certain aluminum alloys are used as mold materials for specific applications where their unique properties are advantageous.

7075-T6: A high-strength aluminum alloy.

Properties: Excellent machinability, extremely fast heat dissipation, and good strength.

Application: Primarily used for prototyping, low-volume production, and for large parts where fast cycle times are critical. The high thermal conductivity of aluminum significantly reduces cooling time in the injection molding process.

3. Other Materials

Copper Alloys: While not used for the entire mold, copper alloys are often used for mold inserts or cores.

Properties: They have exceptional thermal conductivity, much higher than steel.

Application: Used in areas of the mold where heat dissipation needs to be maximized to reduce cycle times and cool difficult-to-reach areas of the molded part.

Why choose Waltay to produce 5-axis CNC Machined Parts in Mold Making?

1. Specialization in Complex Geometries

Waltay excels in 5-axis CNC machining, the specific technology required to create the intricate 3D cavities and curved surfaces of modern molds. Their advanced machinery and skilled programmers can machine complex geometries in a single setup, eliminating the need for manual re-clamping and ensuring a level of accuracy impossible to achieve with 3-axis machines. This directly translates to flawless mold inserts that produce a perfect final product.

2. Expertise with Mold-Specific Materials

Mold making relies on specialized steels that are difficult to machine but essential for durability. Waltay has extensive experience with materials like P20, H13, and NAK80. They understand how to precisely machine these materials to the correct hardness and finish, ensuring the mold can withstand the high pressure and wear of repeated production cycles.

3. Comprehensive, Integrated Service

The mold-making process involves more than just machining. Waltay offers a full-service approach that streamlines the entire workflow. This includes a critical Design for Manufacturability (DFM) analysis to optimize the mold design before cutting, in-house post-machining treatments like heat treating, and coordination with specialized services like EDM for sharp internal corners. This integrated model reduces a client's logistical burden and risk.

4. Uncompromising Quality Assurance

A single flaw in a mold can ruin an entire production run. Waltay's commitment to quality ensures every mold component meets the highest standards. Our adherence to ISO 9001 and use of precision equipment like Coordinate Measuring Machines (CMMs) guarantee

Waltay is specializing in custom CNC machined parts for over 15 years. We are good at making high precision metal and plastic components. We also provide one stop service such as part design, prototypes, mold making, plastic injection and part assembling to better meet customers’ needs. Beside aluminum CNC machined parts, we also provide stainless steel, ABS, PC, PA,PP and POM CNC machined parts which can be widely used in cables, sensors, motors,connectors, etc.

Waltay is specializing in custom CNC machined parts for over 15 years. We are good at making high precision metal and plastic components. We also provide one stop service such as part design, prototypes, mold making, plastic injection and part assembling to better meet customers’ needs. Beside aluminum CNC machined parts, we also provide stainless steel, ABS, PC, PA,PP and POM CNC machined parts which can be widely used in cables, sensors, motors,connectors, etc.