How to effectively control mold trial cost

Generally, molds consist of two parts: an upper mold and a lower mold. The material is placed between the upper and lower molds, and shaped under the action of a press. When the press opens, the workpiece determined by the mold shape is obtained, or the corresponding waste material is removed. So how can we effectively control the cost of mold trial production?

I. Reasonable mold structure design

To effectively control costs, meticulous planning is needed in the design stage. The mold structure design has a significant impact on trial production costs. Accuracy in design is crucial to reduce later modifications. A reasonable mold structure design can reduce material usage, reduce processing difficulty, improve mold service life, and improve production efficiency.

The mold design should undergo thorough collective review. If any unreasonable aspects exist in the mold structure, they should be promptly changed to avoid further modifications or overall changes during the trial production process, which could lead to exceeding the budget.

II. Suitable mold materials

The choice of mold material significantly impacts trial production costs. Common mold materials include steel and aluminum. Steel, with its high wear resistance and strength, is suitable for mass production; while aluminum, with its good thermal conductivity and low processing cost, is suitable for small-batch production. When selecting mold materials, comprehensive consideration should be given to factors such as the product's usage environment, production quantity, and cost budget to find the most suitable material.

Insufficient understanding of material properties, even inaccurate shrinkage rates, frequently occur. Therefore, it is crucial to understand the physical properties of the material before designing the mold to effectively reduce the number of trial productions. Only by understanding the raw materials can one manufacture the expected product. Failure to conduct a thorough collective review of the mold design, resulting in unreasonable aspects of the mold structure, necessitates multiple improvements or overall changes after trial production, exceeding the budget.

III. Optimize mold processing technology

Reasonable control of the mold processing technology can reduce processing difficulty and time. During processing, attention should be paid to design optimization, reasonable cutting paths, reduction of processing steps, and avoidance of repeated processing and waste generation, achieving refined processing. Rational selection of processing equipment and tools, improving processing precision and efficiency, also helps to reduce trial production costs.

Some molds are well-designed, but inadequate processing can lead to an endless increase in the number of trial productions, directly increasing the mold cost.

IV. Adopt advanced technologies and equipment

With continuous technological advancements, advanced technologies and equipment can significantly improve production efficiency and quality while reducing trial production costs. For example, using CNC machining equipment, laser cutting equipment, and rapid prototyping technology can reduce manual operation and processing time; at the same time, advanced materials and coating technologies can improve the service life of the mold and reduce the frequency of mold replacement.

Appropriate molding equipment must be selected during trial production. Even if the mold is well-made, the resulting product may not be ideal, increasing the number of trial productions and directly increasing the mold cost. This is a common problem for small mold factories. Taizhou Huacheng Mold has multiple hydraulic presses to address many problems.

V. Minimize the number of mold trial productions (avoid unnecessary repetitions)

If a mold cannot be put into use after multiple trial productions, in addition to fines as per the contract, the longer the mold stays in the factory, the higher the processing fees and costs become. Multiple or uncontrollable trial production runs are a major blind spot in mold cost control.

Based on a thorough on-site investigation and obtaining firsthand information, correctly listing the problems has already solved half the problem, and then proceed to analyze and resolve it.

Question:

Suppose: We spent 100,000 RMB to make a small mold with a cycle time of 30 seconds and a mold life of 300,000 units. The mold was made, and the sample size and physical properties met the requirements. However, due to difficulties in part removal, the cycle time increased by 30 seconds, and the mold became unusable after producing 100,000 units. To meet the vehicle assembly schedule, another mold needs to be produced. Considering the situation with the original mold, three sets of molds are required. For the same amount of money, some believe the cost of this mold is 3 or even 6 times the original budget. Do you have any different opinions?