CORE & MOULD MAKING

core-mould

MOULD DESIGN:

GST has enabled customers across industries to achieve faster product innovation, improve operational efficiencies and shorten the time-to-markets. We provide the best design solution for your Mould and Die design requirement.

MOULD:

The mould or die refers to the tooling used to produce plastic parts in moulding. Traditionally injection moulds have been expensive to manufacture and were only used in high-volume production applications where thousands of parts were produced. Moulds are typically constructed from hardened steel, pre-hardened steel, aluminium, and/or beryllium-copper alloy. The choice of material to build a mould from is primarily one of economics. Steel moulds generally cost more to construct but offer a longer lifespan that will offset the higher initial cost over a higher number of parts made before wearing out. Pre-hardened steel moulds are less wear resistant and are primarily used for lower volume requirements or larger components. The hardness of the pre-hardened steel measures typically 38-45 on the Rockwell-C scale. Hardened steel moulds are heat treated after machining, making them superior in terms of wear resistance and lifespan. Typical hardness ranges between 50 and 60 Rockwell-C.

 WE ARE SPECIALIZED IN

Injection Mould Design
Sand casting Die Design
Gravity die Casting
Pressure Die casting design(PDC, LPDC)

INJECTION MOULD DESIGN

Injection moulding is one of the major processes for converting thermoplastics from pellet or powder form to useful products. The process involves heating the pellets or powder until it reaches the liquid state. The plastic is then forced into a cooled mould cavity, where it is held under pressure until the plastic returns to its solid state the process involves high pressures. Tooling is expensive and requires long lead time.

We offer services to the Automotive, Electrical and Electronics, Medical and Commercial Product industries.

OUR DESIGN INCLUDES:
• 2D Concept
• 3D Assembly
• Core Cavity separation
• Detail Drawing
• Electrode Design

SAND CASTING DIE DESGIN

Sand casting as a process has been around for thousands of years. It involves creating a shape, encasing it in sand and then removing the original to leave a cavity. This is the sand mould into which molten metal is poured, left to cool and then broken out to reveal a casting. The industrial revolution, technology, new materials, knowledge and skill levels may have made things more sophisticated, but essentially the principle remains the same.

Many castings i.e. bollards and columns are not solid but have hollow centres or cavities. To create a cavity the internal shape of the casting is formed by making a sand core, which is then placed in the mould cavity. The molten iron runs between the mould and the core which, when the sand from the core is removed, leaves a hollow casting.

OUR DISIGN INCLUDES:
• 2D Methoding (Robo Line & Manual)
• 3D Methoding (Robo Line & Manual)
• Calculations
• Core Box Design
• Pattern Design
• Core Box Process
• Simulation
• Detailing Drawing, Etc.,

 

GRAVITY DIE CASTING

Sometimes referred to as Permanent Mould, GDC is a repeatable casting process used for non-ferrous alloy parts, typically aluminium, Zinc and Copper Base alloys. The process differs from HPDC in that Gravity- rather than high pressure- is used to fill the mould with the liquid alloy. GDC is suited to medium to high volumes products and typically parts are of a heavier sections than HPDC, but thinner sections than sand casting.

There are three key stages in the process.

  1. The heated mould [Die or Tool] is coated with a die release agent. The release agent spray also has a secondary function in that it aids cooling of the mould face after the previous part has been removed from the die.
  2. Molten metal is poured into channels in the tool to allow the material to fill all the extremities of the mould cavity. The metal is either hand poured using steel ladles or dosed using mechanical methods. Typically, there is a mould “down sprue” that allows the alloy to enter the mould cavity from the lower part of the die, reducing the formation of turbulence and subsequent porosity and inclusions in the finished part.
  3. Once the part has cooled sufficiently, the die is opened, either manually or utilising mechanical methods.

OUR DESIGN INCLUDES:
• 2D Methoding
• 3D methoding
• Core Box Design
• Patterns
• Equipment Design, Etc.,

PRESSURE DIE CASTING DESIGN (PDC, LPDC)

 

Die casting is a manufacturing process that can produce geometrically complex metal parts through the use of reusable moulds, called dies. The die casting process involves the use of a furnace, metal, die casting machine, and die. The metal, typically a non-ferrous alloy such as aluminium or zinc, is melted in the furnace and then injected into the dies in the die casting machine. There are two main types of die casting machines – hot chamber machines

OUR DESIGN INCLUDES

  • 2D Methoding
  • 3D methoding
    • Concept Design
    • Die Design etc,