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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.

Fabricate the Parts You Need with Custom Machining

When & Why You Need Custom Machining

Custom machining refers to creating or producing metal parts that do not exist anywhere else. It can take any form of machining, including turning and milling. A custom metal part may be as simple as one gear for a mechanism, but it is required in a particular nonstandard size or material or is a new invention that suppliers don’t yet have, calling for a custom production part.

Industries That Require Custom Machining

Nearly all industries require tailored or contract machining. If a business is searching for accurate parts that are sometimes complex to produce using traditional methods, custom machining comes in handy. Some of the industries that require this kind of specific machining include:

  • Aerospace and Defense – Items produced for this industry can include flight safety equipment or parts needed for a specific aircraft.
  • Agriculture– Some items tailored for this industry include farm vehicles and farming tools.
  • Automotive– Motorcycle or vehicle parts and all accessories can be produced using machining.
  • Construction– This category may include heavy construction equipment that does not exist anywhere, particularly if the equipment is a unique design.
  • Electronics – This custom machining can include the production of semiconductor parts, enclosing cases, and others.
  • Firearms – There are many small metal parts needed for ballistic devices.
prototype parts

The Benefits of Prototype Tooling

When custom injection molding is done without a prototype parts stage, this generally leads to a series of production tool adjustments that are both disruptive and costly. Some production managers misperceive a saving to be made for skipping prototype tooling, but those quickly evaporate with the higher risk of a defective part causes legal expenses and other related costs.

Depending on the complexity of the application, prototype parts generally account for about 20-40% of overall production tooling costs. It’s not a small investment, but it’s well worth it when you consider these top three advantages.

Testing Different Plastic Materials

Any plastics made can be more efficiently performance-tested and comparisons assessed without a large financial investment. Having the benefit of physically evaluating prototype parts is a major advantage in making a final selection.

Confirming Part Geometry Feasibility

This is the best opportunity to see if the prototype parts perform properly without defects. If there are problems, it is somewhat simple to revise the prototype tool with cuts or welds.

Reducing Production Time

Overall, it is faster and less costly to make changes to prototype parts compared to the production parts. The ability to design, create, and revise prototype tools is a competitive advantage in the industry. It can lead to a final design that needs fewer revisions to the production tool, saving time and money on the project’s production end.