Blog

Reverse Engineering Made Easy with 3D Light Scanner

Laser Scanning Crucial for Reverse Engineering and Inspections

Any other technology can’t match the precision offered by modern laser scanning equipment. In this blog post, we’re going to look at how these scanners provide essential services for companies.

When you have a specialized part that you need to replicate but don’t have the designs for it, reverse engineering is the path to take. A high-speed 3D laser light scan from machines such as the ATOS 5 and the ATOS Scan Box 6 that we have here at Decatur Mold Tool & Engineering, Inc., will provide the minute detail that you need. With these specifications in hand, it will be easy to recreate the part in question.

That same precision scanning is advantageous when you need to inspect a component thoroughly. With an irregularly shaped object, it can be difficult to get an accurate picture of its condition by using traditional inspection methods. A laser scanner will inspect and record every detail of the object’s surface, regardless of its construction, to deliver the data you require. You will then have a clear indication of the fitness of the part backed by measurable and factual results.

We’re always happy to discuss reverse engineering further at Decatur Mold Tool & Engineering, Inc., so please don’t hesitate to contact us with your question.

Building Quality Injection Molds

What Injection Mold Builders Do

Plastic injection molding is a cost-effective way to create products by injecting molten material into a mold and allowing it to cool and solidify. The molds may be virtually any shape or size, facilitating the production of anything from plastic packaging to furniture and automotive parts. As injection mold builders, we design and manufacture the custom molds necessary for the process.

For over half a century, Decatur Mold Tool & Engineering, Inc. has been a premier plastic injection mold making company, serving clients from industries such as:

  • Aerospace
  • Appliance
  • Automotive
  • Container
  • Medical
  • Military

Our equipment includes nine Nissei injection molding machines ranging in tonnage from 72 to 946. The people operating our machinery are highly experienced process technicians and quality control specialists, all dedicated to producing the finest molds possible. There is virtually no project we cannot handle.

Endless Possibilities

Injection molding began in 1872 with simple products like buttons. Thanks to technological advancements, today’s injection mold builders can create molds with extremely complex geometries, facilitating the cost-effective mass production of endlessly diverse products.

Contact us today to discuss the specification of your application. Based on the details provided, we will mock up a design for your mold, create a sample, and quality test it to ensure it meets your demands.

Innovation Through Reverse Engineering

What Is Reverse Engineering For Injection Molding?

Reverse engineering reproduces a product by following a detailed examination of its construction or composition. It is attempting to duplicate the product, or mold, by taking all the original dimensions and recreating it. Manufacturers often use this process to remake molds for plastic parts when the original design files are lost or no longer exist. The closest comparison is in redeveloping parts for vehicles that are no longer manufactured.

Replicating An Original

Reverse engineering differs from an original design mainly because manufacturers don’t create the mold from scratch. The design team aims to duplicate an existing part to the exact specifications of the original. Once the mold is complete, the piece can be fabricated without limit.

Practical Processes

The process must include several considerations, such as shape, function, and material reversal. The practical application of reverse engineering for injection mold manufacturing primarily comprises:

  • The design of new parts for product modification or profiling
  • Duplicating existing parts to reproduce the original product’s design intent
  • Restoring damaged or worn parts
  • The detection and comparison of digital models

Reverse engineering technology provides good technical support for rapid design and prototyping. It’s one of the most essential and concise ways of information transmission in manufacturing.

Varieties of Tool Designs

The Factors That Affect Tool Design

When it comes to tool design, entire teams are dedicated to their creation and function. That is why companies like Decatur Mold Tool & Engineering Inc. pride themselves on using precision machines and computer programming that create the best finish for their customers. They have the technology to take the dimensions and measurements given to them by customers and manufacture the perfect tools for their use.

Multiple factors contribute to tool design so that they make life easier for the industrial field and everyone in general. We use tools every day in every scenario, at home, at school, and at work. This is why designers must consider the following:

  • The Function of the Tool
  • Size and Type of Machine Tool
  • Number of Components
  • Aesthetic (in some cases)
  • Environment
  • Types of Workpiece Material
  • The Degree of Accuracy
  • Interaction with User
  • Interaction with Other Components and Buildings
  • Safety
  • Availability of Material, Tools, Technology, and Expertise
  • Trends

Tool design is meant to make help make things more streamlined and convenient. That is why companies like Decatur Mold Tool & Engineering are highly reliable in ensuring the designs are manufactured to perfection. Contact them today to learn more about their products and services.

Precise Work with CNC Machining

CNC Machining Vs. Conventional Machining

At the end of the day, both CNC machining and conventional machining aim to achieve the same goal using the same raw chunk of plastic or metal. The difference between the two is how they are able to achieve this goal.

Conventional machining can be effective when it comes to small-quantity projects, especially since it can typically cost less than CNC machining. A highly skilled operator sets the gears during the machining process to help create a part that is as close to your requirements as possible.

If you need a large quantity of precision parts and want them quickly, then you want to look into CNC machining. Fully automated, this process improves speed, production rate, and accuracy when compared to the manual nature of conventional machining. This makes it the best choice when you need to create a quantity of parts all at once or need something with complex concave or convex arcs, imperial and metric threads, or two tapers of differing degrees.

The key to deciding between CNC machining and the conventional option is how many pieces you need. The more significant the amount, the more you should consider CNC as your machining option.

Custom Machining For Your Business

Benefits of Custom Machining to Your Business

Many suppliers state they deliver custom machined parts; however, customers can sometimes be left with a piece that is unsatisfactory for their needs. One major cause of dissatisfaction is that suppliers will often utilize a part they have already created and modify it. Reliable custom machining experts like those at Decatur Mold Tool & Engineering, Inc. create truly custom parts for each order request.

Professional custom machining offers these crucial benefits for your business:

Time Savings

One of the biggest benefits of custom or CNC machining is that you don’t waste time and money looking for parts that are no longer in production and so may not be readily available from a third-party vendor. The right custom machining shop can take your specifications, create the parts you need, and deliver them to you in less time than it takes you to search.

Specifications Are Always On File

After your first order, your part specifications are kept on file so that the next time you need replacement parts, they are ready. The convenience and peace of mind that comes with knowing you can place your custom machining order on Monday, and the parts will be in your inventory by the end of the week cannot be overstated.

Reduce Lost Production Time

Every hour you have to wait for a custom part to arrive, your business is losing money. Your machines are down, and you are paying your employees. Building a partnership with a reputable custom machining shop means you get help in an urgent situation and have your machines up and running again with minimal delay.

Reverse Engineering for Innovation

Benefits of Reverse Engineering in Manufacturing

The manufacturing sector looks at reverse engineering as an important way to sustain competition or as a tool to understand the flaws in a design and to re-work it. The process may differ between manufacturers, yet it is evident that the rise of reverse engineering has gained momentum, and the integration of CAD tools has amplified its impact. Here are a few benefits that come with the use of reverse engineering in product innovation.

Filling Up Voids in Design Information

Reverse engineering is applied to discover or develop full design information about obsolete components. It is of utmost importance to have accurate design data documentation for production efficiency in computer-aided manufacturing.

Figuring Out Why Products Failed

Reverse engineering is also critical for product failure investigation and extending the product’s functional life cycle. For example, if a component like an engine crankshaft is showing signs of premature failure, it can be investigated by applying reverse engineering methodology. These stress regions or cracks can be identified and improved.

Improving Manufacturing Processes

The concept of reverse engineering is not restricted to analyzing product designs. It is also applied to make a product easier and faster to manufacture without compromising on quality or performance. Identifying the most cost-efficient way to manufacture components is crucial for lean manufacturing and is hugely beneficial in cost savings and quality control.

Injection Molding Services for the Tools you Need

Injection Molding Services — Tooling

When it comes to our business, we know the exact tools and equipment needed to ensure everything is running smoothly. Everything has its purpose for keeping production going, which is why when any of those essential tools break, it can make things a little complicated. That’s why companies like Decatur Mold Tool & Engineering, Inc. is specialized in injection molding services for manufacturing precisely what you need using high-quality plastic materials.

The process where the mold is being made is called tooling. In other words, you can think of it as a tool design so that the right parts are sent to customers. The process requires some highly skilled technicians that understand how to create top-quality parts with tight dimensions. It requires suitable materials to ensure the manufactured pieces will last for many years. The beauty of injection mold services is that the tooling can be tailored to the needs of each customer, and in the case of more common machinery, it can be reused by anyone who needs it. This makes the process quick, precise, and seamless.

Contact Decatur Mold Tool & Engineering, Inc. for more information about their injection mold services and tool design. They’ll be glad to answer any inquiries you may have.

Reliable Plastic Molding Services

The Reliability of Plastic Molding Services

The diversity of uses for plastic in today’s society makes plastic molding services an important cog in every industry. Melted and made with different materials and chemicals, plastic can truly be shaped into almost anything you see on the market today. Companies like Decatur Mold Tool & Engineering, Inc. are dedicated to manufacturing precisely what you need using state-of-the-art technology.

What exactly do plastic molding services entail? Also known as plastic injection molding, this process consists of resin in a barrel that’s heated to a molten state before being shot into a mold to form a final production-grade thermoplastic part. These molds are usually designed for reuse with exact measurements and features to ensure customers continue to receive the best quality components. These services are essential to making sure various industries can quickly get high-quality parts and pieces without fear of scrambling to search for a part that might be very difficult to find pre-made.

The benefits of mold manufacturing are something Decatur Mold Tool &Engineering, Inc. can deliver. Contact them today to learn more about their services; they’ll be happy to discuss details about specific parts you need to have made.

Producing Better Tools and Parts with CAD Drawing

Why CAD Drawing Is Beneficial In Tool Prototyping & Production

CAD is a type of software that many industries rely on to create drafts and models before the production process. CAD design services are useful to design 2D drawings and 3D models with precise measurements. Industries like engineering, industrial design, architecture, and product design can all use CAD design for development cycles and for improving their productivity by leaps and bounds.

There are many benefits of using CAD software for prototype tooling. Studies have shown that integrated CAD usage enables product development companies to meet their goals more efficiently, improving product development time and quality, which translates to reduced manufacturing costs. Here are the two biggest benefits of CAD design services:

Increased Productivity

CAD software lowers production costs by helping designers work faster and smarter. This then allows those companies to produce high-quality, low-cost products and increases their output levels as well by being able to make design changes on the fly when necessary. This is a huge competitive advantage in the global marketplace.

Higher Quality Designs

Historically, when a design didn’t turn out as expected, the team needed to go back to the drawing board. Using CAD design services gives design teams better control of the quality of the final engineered product.  It is now much easier to investigate errors, diagnose problems, and enact solutions before any prototypes are made.