Our Process
Step 1: Defining the Application
The process starts with a definition of the application and the intended use for inter-mold ® technology.
Function of Closure System
The first step in evaluating the suitability of inter-mold ® to a product or process is defining the application or intended use. The easiest way to communicate this information is with sample parts, pictures, and drawings.
Material (Resin) Properties
The inter-mold ® process can be used with a wide range of plastic resins. Some of the common materials used are polypropylene, polyethylene, polystyrene, nylon and other semi- flexible thermoplastics. Suitability of any particular resin involves an evaluation of the melt- flow index, flex modulus, impact resistance and tensile strength of the material.
Hook Design
Different hook designs can be employed depending on the application and nature of the woven, non-woven and knitted loop materials used for engagement. Hooks can range from weaker to stronger attachment as necessary. The requirements necessary to determine an appropriate hook shape are part of describing the closure system.
Step 2: Feasibility Study
This process consists of several steps including molding sample cards, evaluating tooling requirements and designing inserts. The final result is a proposal for implementing inter-mold ® with estimates for all fixed costs and license fees.
Sample Customer Resin
The underlying part material is an integral part of the closure system with inter-mold ® . In order to correctly specify a hook shape and pattern, sample cards are produced using the customer resin. Customers are encouraged to send a sample (approximately 10 pounds) of their existing resin to be tested in an inter-mold ® tool.
Mold Analysis
The hooks formed during molding are readily released from injection molds because plastic parts retain some flexibility before they completely cool. The hook shapes have been designed with gently curving bases to facilitate releasing.
Design Inserts
Inserts are either Flat or Contoured. Any insert can be Surface Mounted or placed on a Retractable Core. The exact insert specification will be determined after evaluation of the mold drawings and part requirements.
inter-mold ® Proposal
Once we have completed the analysis of the application, selected resin, mold drawings, and insert specifications, a proposal for implementing inter-mold ® will be provided. This proposal will include cost estimates for building the inserts and adding them in a production injection mold.
Step 3: Development
The work to add inter-mold ® inserts to a standard injection mold can be performed by any qualified tool shop with guidance from our parent company APLIX. APLIX has performed extensive tests with tooling methods and materials to achieve maximum efficiency. The tool steel material and plating are matched to each individual plastic resin to achieve optimum performance.
Execute License Agreement
The development of mold inserts is the beginning of a license arrangement with APLIX.
Build Inserts
The time required to build the inserts is dependent on the complexity of the design. Flat inserts can be built in less than two weeks, while complex contoured inserts may take up to four weeks.
Modify Molds
A vendor will be selected to perform mold modification during the Feasibility Study. Space for the inserts is typically machined out using a high precision process.
Step 4: Production
First Shots and Production Sign Off
The final phase of implementing inter-mold ® is to establish operating parameters. This process begins by running the mold using standard (before inter-mold ® ) settings and evaluating the resulting parts.
We can assist in tuning molding operations to ensure process stability and high quality parts. During these first shots, production personnel will become familiar and comfortable with inter-mold ® technology.
Preventative Maintenance
No special tooling preventive maintenance programs are required for inter-mold ® inserts. Care must be taken when repairing or retrofitting tooling areas adjacent to inter-mold ® inserts.