In-House Full-Service Toolroom
Single-Cavity to 96+ Cavity Molds
Documented Maintenance, Revisions, and Repair Services
Tool Design for Manufacturability
Actions, lifters, and unscrewing
Valve-gate, hot-tip, cold-runner, 3-plate
We have invested in an extensive inventory of master mold bases. These frames have interchangeable inserts which allow for quicker and less expensive mold designs. We make these mold frames available to house your unit molds and tool sets when your molded product is compatible with this type of tooling. This saves you thousands of dollars in tooling costs.
Part Design Guidelines
The “Injection Molded Part Design Guidelines” will review items to consider when designing your next plastic component like:
- Maintaining uniform wall thickness to minimize sinking, warping and improve mold fill.
- Using generous radius at all corners to avoid sharp corners that increase stress concentration which can lead to part failure.
- Incorporating sufficient draft angles for easy removal of the part from the mold.
Mold Design Guidelines
Crescent Industries’ mold design engineers look at the aspects of the part that are important for injection molding. Adherence to these design principles and best practices at the beginning of the design process will ultimately lead to better overall quality of parts during manufacturing. These “Mold Design Guidelines” will evaluate items like the follow:
- Gate Designs / Runner Designs
- Cooling / Venting
- Mold Filling
MUD (Master Unit Die): The choice when a “dedicated or stand alone” mold base is not required. The part, runner and gate geometry are cut into standardized inserts that fit into the frame
Unscrewing Molds: Used when there is a requirement for male or female threads on a plastic component
Hot Runner System: An assembly of heated components used to inject molten plastic into the cavities of the mold
Action Molds: Includes mechanical action incorporated into the design when a hole, slot, undercut or thread is needed that is not perpendicular to the parting line
Two Plate Molds: Provides one parting line and the mold splits into two halves; the sprue, runners, gates and cavities are all on the same side
Three Plate Molds: These molds will have two parting lines and are used because of their flexibility in gating location
Protect Your Investment
Once a mold has run a set number of cycles; inspections, maintenance and cleaning should be performed. Different types of molds age at different rates, so scheduling maintenance needs to be documented carefully. Our knowledge and experience gives us the ability to determine the best mold maintenance schedule specific to each injection mold.
Injection mold repairs can be costly. This means it is critically important for injection molds to receive regular maintenance; this is simply the best way to protect your investment and maintain consistent production of quality plastic components. With our on-site tooling facility we provide quick and efficient mold repairs or revisions.
Crescent Industries utilizes CNC automated equipment and highly skilled journeymen and machinists to produce custom and complex precision components. Our equipment includes several horizontal and vertical CNC machining centers, Die-Sink EDM’s, Wire EDM and a 3 Axis/2Axis machining center with a rotary table and capabilities for tombstones and automatic tool changer which achieves extended machining hours and continuous operation. We have invested in CMMs which are located in our tooling facility to perform quality inspections during the machining process to verify precision and accuracy.
Assembly & Packaging
Insert Molding reduces assembly and labor costs, reduces the size and weight of the part, improves component reliability and delivers improved part strength and structure with enhanced design flexibility by incorporating metal and plastics or multiple combinations of materials and components into a single part. The process makes use of engineering plastics for improved wear resistance, tensile strength and weight reduction as well as using metallic materials for strength and conductivity.
Inserts can be molded into a diverse range of critical plastic components. These components can be used in housings, instruments, knobs and electrical components. Which can be utilized in the medical, defense, aerospace, electronics/electrical, industrial and consumer markets.
Surface Mount Pads
Over molding has developed into a rather standard process in the field of injection molding. We all enjoy the lightweight, durability, look and feel of modern plastics. Over molding is basically the process of injection molding two different plastics, one on top of or around the other. This results in a single structure that is strong and rigid on the inside yet flexible, colorful and easy to hold on the outside.
The variety of textures also makes over molded products more comfortable and easy to use, ultimately providing more personalized products. This process helps to contribute to safety by making components shock absorbent and covers potentially harmful corners and edges. The best way to produce over-molded plastic components is with a vertical/vertical injection molding machine. As it relies on the gentle force of gravity to clamp the inner and outer parts together.
The advantage of Family-Molding is that the tooling costs decrease and part prices become lower verses a single-cavity tool. However, family tools can be challenging & difficult due to the natural imbalance of material flow in the cavities. Our Engineers have mastered this process ensuring optimal results.
This molding process produces a set of various shaped components molded at the same time and are manufactured from the same material. These injection molds are often ran to produce parts in a set at the same time, individually or in groupings. We utilize mold-fill simulation to learn how parts will fill in the mold to prevent potential problems in the design phase before the tool is actually built. Crescent utilizes sequential valve gating in order to improve performance, reduce variation, and improve balance during the injection molding process.
Crescent’s Core Capabilities
Single-cavity to complex 96 multi-cavity tools including documented tool transfer process & scheduled preventative maintenance programs. Our In-House capabilities offer complete solutions.
Offering a comprehensive range of skilled labor, collaborative robots and automation. Our kitting and value add services lead the industry with solutions for complex assembly projects.