(Transport Packaging) What types of molding dies are used for thermoformed products?
Apr 01,2022
Plaster mold
Primarily, yellow thermoformed prototype plaster powder is used. If drawings are provided, the mold is fabricated using milling and manual techniques based on the drawing’s dimensions and specifications. If a physical sample is supplied, its outline is first replicated in modeling clay to create a mold, which is then vacuum‑formed into a vacuum‑molded cover; the plaster mold is subsequently extracted and refined. The entire process typically takes 2–4 days.
Plaster molds are easy to produce and require relatively little time, making them well-suited for modifying product packaging. They are also cost-effective, but their durability is limited; after a period of use, they tend to deteriorate more readily, and the resulting products often exhibit lower transparency. These molds are primarily used for first‑article approval and for products where external packaging transparency is not a critical requirement.
Rubber mold
Typically, following the product design specifications, a plaster mold is first created. A vacuum shell is then produced using this plaster mold, and a specially formulated high‑temperature‑resistant resin is injected into the shell. Once the mold has fully dried, drilling and polishing are carried out, a process that takes approximately 3 to 5 days.
Resin molds are more expensive than copper and plaster molds, but their service life is comparable to that of copper molds. They are more durable and can address certain technical challenges that copper and plaster molds cannot, such as water‑marking on product walls; using these molds yields better results. They are particularly well suited for thermoformed products in industries like electronics, toys, pharmaceuticals, food, and automotive accessories—where specific performance requirements apply.
Bakelite mold
We manufacture a wide range of bakelite molds using imported heating materials, Japanese‑made high‑temperature adhesive tape, and premium copper rivets. These molds feature uniform heat distribution and excellent sealing performance, making them compatible with various disc‑type sealing machines, Taiwan‑made push‑pull sealers, and fully automatic chain‑type sealing machines. They are primarily used for heat‑sealing packaging of paper cards and blister packs.
Electrolytic copper mold
According to the product design specifications, after fabricating a plaster mold, a vacuum cover is produced using this mold. The vacuum cover is then placed in an electrolytic tank; once the coating reaches a thickness of 5–8 mm on the surface, the mold is filled with plaster, vent holes are created, and the mold’s surface is polished smooth before it can be used. This process typically takes about 3–5 days.
Belonging to the category of metal molds, these tools are highly durable, producing parts with superior appearance and transparency. They are relatively inexpensive to manufacture and widely applicable, making them the preferred choice in most cases. They are particularly well-suited for high‑quality thermoformed products in industries such as electronics, toys, stationery, cosmetics, automotive accessories, and more.
Aluminum alloy formwork
Based on the provided blister‑molding drawings or samples, data is entered into the computer, and the CNC lathe performs the machining automatically. Subsequently, additional operations such as drilling and creating undercuts are completed by hand, after which the mold is polished to a smooth finish and is ready for use; this process typically takes 5–7 days. The molds are manufactured using CNC machining and are made from aluminum alloys such as ZL401, 6061, and 7075.
These molds offer high precision, producing parts with aesthetically pleasing contours and angles, and they are exceptionally durable—making them the most expensive of the four mold types. They are ideally suited for products in industries such as electronics, gifts, toys, pharmaceuticals, and stationery, where both appearance and dimensional accuracy are critical. In fact, alloy aluminum molds are the preferred choice for large‑volume, high‑specification thermoforming production, offering superior longevity, time and energy savings, high productivity, and an extremely low scrap rate compared to plaster, copper, or plastic molds.
Heat-sealing mold
The heat-sealing molds are crafted from premium copper or aluminum alloy, specifically addressing the challenges of high‑frequency heat sealing for PET. The surface is coated with Teflon to prevent PET from sticking. The edge‑pressing patterns are CNC‑engraved, ensuring crisp lines and uniform, consistent dimensions; custom designs can be tailored to meet specific customer requirements.
High-frequency mold
The high-frequency mold is made of premium pressed‑line material, and the cutting blade is a laser cutter, ensuring clean, burr‑free edges and effortless material tearing. The edge‑pressing pattern is computer‑engraved, with crisp, uniformly sized lines; custom patterns can be tailored to meet specific customer requirements. Aircraft‑style holes can be produced based on provided samples or technical drawings. This equipment is primarily used for sealing double blister packs (PVC or PETG).
Die, punching die
Primarily used for blanking and punching (round holes, aircraft‑type holes, and butterfly‑shaped holes).
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Blow-molding molds are something we often see and use, yet many people assume their design is straightforward. But do you really know how to design a blow-molding mold? Let’s examine the key considerations during the design process. ### 1. Mold Opening Direction and Parting Line At the outset of designing any blow-molded product, it’s essential to determine the mold opening direction and parting line. This ensures minimal reliance on core‑pulling mechanisms and eliminates visible parting lines that could affect the product’s appearance. ### 2. Draft Angle 1. An appropriate draft angle helps prevent surface defects such as stringing or fuzziness. For smooth surfaces, the draft angle should be ≥0.5°; for textured (sanded) surfaces, it should exceed 1°; and for rough-textured surfaces, it should be greater than 1.5°. 2. Proper draft angles also help avoid top‑surface damage, including whitening, deformation, or cracking at the product’s apex. 3. When designing deep‑cavity products, the outer surface draft angle should ideally be steeper than the inner surface draft angle. This prevents core misalignment during molding, ensures uniform wall thickness, and maintains material strength at the product’s opening. ### 3. Wall Thickness 1. Different plastics have specific recommended wall‑thickness ranges, typically between 0.5 mm and 4 mm. If wall thickness exceeds 4 mm, cooling times become excessively long and shrinkage issues may arise; in such cases, consider revising the product’s geometry. 2. Uneven wall thickness can lead to surface shrinkage. 3. Irregular wall thickness may cause porosity and weld lines. ### 4. Reinforcing Ribs 1. Appropriately applied reinforcing ribs enhance product rigidity and reduce deformation. 2. The rib thickness must not exceed 0.5–0.7 times the product’s wall thickness; otherwise, surface shrinkage may occur. 3. The single‑side slope of reinforcing ribs should be greater than 1.5° to prevent top‑surface damage. Blow-molding molds are something we often see and use, yet many people assume their design is straightforward. But do you really know how to design a blow-molding mold? Let’s examine the key considerations during the design process. ### 1. Mold Opening Direction and Parting Line At the outset of designing any blow-molded product, it’s essential to determine the mold opening direction and parting line. This ensures minimal reliance on core‑pulling mechanisms and eliminates visible parting lines that could affect the product’s appearance. ### 2. Draft Angle 1. An appropriate draft angle helps prevent surface defects such as stringing or fuzziness. For smooth surfaces, the draft angle should be ≥0.5°; for textured (sanded) surfaces, it should exceed 1°; and for rough-textured surfaces, it should be greater than 1.5°. 2. Proper draft angles also help avoid top‑surface damage, including whitening, deformation, or cracking at the product’s apex. 3. When designing deep‑cavity products, the outer surface draft angle should ideally be steeper than the inner surface draft angle. This prevents core misalignment during molding, ensures uniform wall thickness, and maintains material strength at the product’s opening. ### 3. Wall Thickness 1. Different plastics have specific recommended wall‑thickness ranges, typically between 0.5 mm and 4 mm. If wall thickness exceeds 4 mm, cooling times become excessively long and shrinkage issues may arise; in such cases, consider revising the product’s geometry. 2. Uneven wall thickness can lead to surface shrinkage. 3. Irregular wall thickness may cause porosity and weld lines. ### 4. Reinforcing Ribs 1. Appropriately applied reinforcing ribs enhance product rigidity and reduce deformation. 2. The rib thickness must not exceed 0.5–0.7 times the product’s wall thickness; otherwise, surface shrinkage may occur. 3. The single‑side slope of reinforcing ribs should be greater than 1.5° to prevent top‑surface damage.
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Every object has a finite lifespan, and to extend its service life, we must understand the proper maintenance procedures. Below are the correct methods for maintaining rubber molds. First, the wear curve of regularly maintained molds exists for every mold. Mold maintenance focuses on addressing abnormal wear that occurs during operation, and the number of stamping cycles completed during this period is easy to track. Once the predetermined cycle count is reached, a maintenance plan can be implemented, making it straightforward to identify maintenance tasks and manage maintenance timing. Second, enhanced maintenance aims to prolong mold life, ensure consistent quality, and simplify upkeep by refining specific mold components through targeted improvements. Third, routine maintenance involves standard cleaning and inspection of rubber molds, as well as lubrication with oil or similar substances. This work typically ensures the mold remains in good working condition, enabling early detection of any abnormalities. Fourth, when rubber molds experience malfunctions during processing—resulting in issues such as excessive burrs, incorrect dimensions, surface defects, or even burnt mold parts—they can no longer function safely. Such abnormalities necessitate immediate repair and maintenance, which is referred to as “accident‑related maintenance.” This type of maintenance is usually performed when the mold is nearing its operational limits; if the cost of maintaining the mold becomes prohibitive, its useful life may be short. Because such repairs often occur unexpectedly, it is essential to have contingency plans in place, including scheduled shutdowns and emergency response procedures.
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