FEATURE TOOLS & TOOLING
SIX KEY QUESTIONS TO ASK YOUR TOOLMAKER
involved in doing so. Toolmakers aren’t moulders so will often
make a tool without understanding the moulding parameters for the production of the final component. This can result in a tool that is not fit-for-purpose. Although Broanmain oversees the tool
design and manufacture from start to finish, we are injection moulders, so we always have the quality of the finished component at the heart of any decision being made. When designing a tool, consider what the final component will look like, the materials it will be made from, even the machines it will be made on. This helps to ensure that the final component will deliver the desired result. 5. How important is it to know what material I’ll be using for injection moulding components when creating my tool? There are two material choices to
by Wilf Davis, managing director, Broanmain A
ccording to Davis, anyone can get a reliable, high-spec tool within a
reasonable timeframe at an affordable price, simply by asking their prospective toolmaker the following questions. 1. Do you produce everything in-house or are some elements of the process outsourced? There’s no problem with outsourcing
elements of the toolmaking process – in fact, this can often help to keep down costs and lead times – but it’s important to find out from the start what these are and how they will be managed, to ensure any outsourcing doesn’t impact on the final quality of your tool. Although full control over the
toolmaking process is retained in- house, by outsourcing certain elements considerable cost savings can be realised and the production process is sped up, ensuring the finished tool is of a high quality. 2. What are the typical mould tool design timescales? These can vary greatly, so it’s important
to clarify the expected timeframe with your prospective toolmaker early on in the process. Due to a decline in the number of UK toolmakers and the fact that one tradesperson usually works on the same tool from start to finish, extremely long waits for a tool to be made – often over a year – are not uncommon. By contrast, Chinese toolmaking firms have several people working on different stages of the
30 APRIL 2019 | FACTORY EQUIPMENT
same tool, so the timeframes involved can be much shorter. On average, it takes us between one and
four weeks to finalise the tool design with our Chinese toolmaking partner. Then another four to six weeks for the manufacture of the tool, and a further week for us to sample the prototype with the commissioning customer. Finally, there’s a six-week shipping time for the final tool. Typically, Broanmain gives an estimated timeframe of between 12-17 weeks from initial design to receipt of the finished tool. However, as with any project, it’s always prudent to factor in a 10 per cent extension to account for unforeseen challenges. 3. Are there any hidden costs? This is a really key area to consider,
especially if you’re importing your tool from overseas. A reputable toolmaker should offer you an all-in price, covering shipping costs, import taxes, customs duty and VAT. Because of our experience in China and
the relationships we’ve built up with our partners over time, we offer our customers a high-quality toolmaking service at a cost-effective price. Our all- in fee covers the design, modifications, manufacture and delivery of the tool, with no unwelcome surprises. 4. Should I get a component production team involved in the prototype? It is possible to design and manufacture a tool in isolation, but there are risks
Factoring in injection moulding parameters is essential in the design tool process
consider when making a tool: the material of the tool itself and the material of the final component. It’s important to use the right kind of steel for the tool, to ensure that it can be fully hardened. We use a nickel-chromium alloy (grade 2767) for our tools, which is ideal. As far as the material for the injection
moulded components is concerned, this is critical because different materials have different shrinkages. An ABS or polypropylene composite will react differently to a material containing glass fillers, for example. This needs to be considered when making calculations for your tool. 6. How much would pushing forward the timescales impact the quality of my tool, and potentially the final quality of my moulded components? It can be possible to make time savings,
for example by using extra manpower, but this brings risks and is not something we would advise doing, as there will invariably be an impact on quality. We always suggest our customers factor additional time into their project planning to avoid having to rush at the end. It’s better to work in a calculated, realistic fashion than a pressurised manner, as this can result in corners being cut. A rushed tool will make for a lower
Broanmain
www.broanmainpl
astics.com T: +44 (0) 1306 885 888
quality moulded component, and is a false economy. If made well, a high-quality master tool will enjoy a long and successful service life, running at least half a million components – in fact, figures upwards of even four million are not uncommon. It’s worth getting it right the first time.
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