THE PROSESS OF MOULD TRIALS
This is the process by which a new mould is perfected in order to produce the desired products as efficiently as possible. This makes it one of the most important aspects of injection moulding. Before the start of the mould trial process, we work on the mould design. Together with our toolmaker we discuss the mould constructions and technical solutions.
We do this to avoid unnecessary mistakes in the mould, and make sure that the first phase of the mould trial (Tier 1) already provides us with a good product.
TIER ONE TRIAL - POLISH THE EDGES
After the toolmaker produces the mould we conduct the first trials. We receive ample visual materials monitoring the moulding process, ‘under the microscope’ imaging of any questionable elements of the components. With our trusted partners, we test whether the product comes out neatly and whether there are any flashes, air traps or deformations.
We draw up a shared report with our findings, in which we specify the modifications that have to be made. The toolmaker then proceeds to optimize the mould and Tier 1 samples are sent to you and our lab to provide a first impression.
TIER TWO TRIAL - YOUR FEEDBACK
Once any imperfections have been resolved, we conduct a new mould trial with the optimized mould. We present the resulting Tier 2 product to you and we inspect it together. Together, we go over the cosmetic aspects and the cycle time. Did we produce an appealing and functional product, are the dimensions correct, can we manufacture it within the calculated cycle time and does it meet your requirements and wishes? Then you are given as much time as you need to conduct test trials on the specific component as needed or required by the product specifics. Then we send the toolmaker another report, which includes your feedback and our additional comments and professional suggestions. A second round of optimization follows.
TIER THREE - THE FINISHING TOUCH
Finally, we conduct a Tier 3 mould trial with the fully improved mould. During this phase, it is all about the finishing touch. For example: choosing between a matt or glossy texture. Once the product has been perfected and every detail checks out, we produce a batch of samples. Once we are convinced that there is no more room for error and the component gets your final approval, mass-production process can begin!
Our relationship does not end here… We will draw the complete 4D picture for you and consult you how to optimize your entire supply chain, production, timing and logistics process.