Tailored Rapid Prototyping Mold Services

 

We have strong engineering design capabilities in product development, production process design, product assembly, and metal mold design and manufacturing. We can provide rapid prototype and model making services according to customer requirements.

Why choose aluminum as a mold?

Aluminum has a reputation as the material of choice for prototypes and short-term production. Over the past few decades, the pressure to shorten the cycle time for manufacturing molds and molded parts has raised the level of interest to a new level.

Under the right conditions, aluminum is also an excellent choice for long-term production.

• Cutting speed is faster than steel
• Faster delivery time
• Cheaper
• Cooling speed is 5 times faster than P20 steel
• Faster cycle times
• Flatter part

“Rapid processing, rapid mold customization”

Low-volume production using aluminum alloy molds
At our factory, with orders for more than 100 pieces, we will implement fast aluminum alloy molds, plastics and die casting. Materials can be plastic and metal. We can customize fast molds for various plastic products according to customer requirements, such as sandblasting, texture, painting, plating and other different surface treatments. We can make the mold life reach 5k to 100k or higher. Therefore, if you have any project and you only need 100 or 100 parts, you are welcome to contact us for a quote.

What to choose for a quick mold?

Fast tooling is a way to simplify the structure of the tooling, enabling low cost and short lead times. It is based on low demand and is often used in the field of rapid injection molding. Our plant produces its own 7075 aluminum (the mold can be textured) and hardened P20 tool steel quick molds for making cavities, cores and ejector plates. They are then installed into a master unit mold (MUD-based system) with standard tool parts to produce injection-molded parts.
Fast mold compared to traditional mold?

Aluminum molds provide low cost durable are pertinent for low-volume production of prototypes and provides a low-cost solution with minimum lead times as compared to contemporary production mold techniques. For fast molds, we are usually 30-50% cheaper than complete production molds, and lead times are shortened by 40-60% compared to traditional molds. Generally, we are able to move from the initial DFM design to mold manufacturing, mold flow analysis and initial samples in approximately 5 to 28 days (depending on product complexity and tool capabilities). Our expertise in rapid manufacturing has really reduced the amount of time and cost of producing prototypes!

What metal materials are used for rapid processing?

We use aluminum, P20, NAK80, and S136 steel to make our molds, which can be run in a standard injection molding machine to produce low-volume production-quality parts. These molds are usually available in more than 5000 to 100,000 units (depending on the mold steel type, prototype material, and mold function).

• If the part requires a normal surface finish, we use aluminum or P20 steel in the injection molding process.
• If a glossy or transparent surface is required, the mold material will consist of NAK80 or S136, which are types of polished steel.

Advantages of rapid prototyping mold tooling

1. Fast processing time is much shorter than traditional molds
2. Rapid processing costs are much lower than traditional molds.

The challenge of rapid prototyping mold

• Die life is shorter than traditional production quantities
• Tolerances are wider than traditional tools.

Rapid prototyping is an innovative technology that can produce objects with complex geometric shapes directly from mathematical models of objects made on 3D CAD systems in just a few hours.

We provide rapid prototyping (using photo-curing, laser sintering, 3D printing technology) services, produce silicone molds, researches and develop new materials to obtain prototypes with excellent surface quality, and achieves detailed and similar functional characteristics of prototypes of finished materials Perfect reproduction.

“We maintain long-term business relationships with many well-known international brand customers, and have established mutual trust and friendly relations.”

If we can help you with your project please call us at 0086-769-82821468 or email sales@kaitomould.com

 

Kaito has been an ISO-Certified cost-effective die casting manufacturer for Aluminum, Zinc, And Magnesium parts Over 10 years.

Not Our Die-casting Factory has good machining and quality checking equipment, but also over 10 years experience, skilled die casting engineering team and technician team provide a full solution from design, development, manufacturing, production, and post-processing for aluminum die casting part, zinc die casting parts and magnesium die casting parts. Kaito manufactures prototyping, low volume, and production die casting mold for today’s demanding manufacturing environment.

 

Kaito Main service for Die casting project:

Production Die casting mold:

Hard tool or H-13 serial steel for die-cast mold is an excellent process for higher quantity requirements. It is a larger upfront mold cost investment, but a significant reduction in re-occurring costs. Production die-cast parts have highly repeatable properties and tolerances.

Typical Lead Time:

• Tooling = 4-8 weeks (depends on part size and structure)
• Samples = 1-2 weeks
• Production (Qty 10k) = 3-4 weeks

Tooling Life Expectancy:

• 300k shot

Prototype mold for die casting:

The term “Soft mold” is used to describe a die-cast mold made out of cheap and soft steel. The running faster feed rates when CNC Machining and simples the mold structure to save mold cost. Typically the mold life and reach 10, 000 to 30, 000 parts before showing any significant wear.

Typical Lead Time:

• Tooling = 2-5 weeks (depends on part size and structure)
• Samples = 1-2 weeks
• Production (Qty 100) = 3-5 days

Tooling Life Expectancy:

• 10k shots

 

Post Machining

Kaito provides CNC machining including milling, drilling, tapping, countersinking, boring and reaming for the machining of die casting parts

Surface Finishes

Not our wide assortment of vibratory deburring and shot blasting equipment, but also we have established relationships with well-qualified suppliers for powder coating, electrostatic painting, anodizing, zinc, copper & nickel plating, and heat treat/stress relieving.

Die Casting Alloys

Not only can die-cast alloys withstand high operating temperatures, but they are also fully recyclable. We routinely pour a broad range of non-ferrous materials. The following are some of the most common alloys being used:

• Aluminum dies casting alloys: A380, AL383 A360, A356, and so on.
• Magnesium dies casting alloys include AZ91D and AM60B.
• Zinc die casting alloys to include ZA3, ZA12, and ZA27, Zamak #3, ZA-8

 

What kind of component you can consider to choosing for die casting?

• What kind of component you can consider to choosing for die casting?
• The part not only needs high process stability but also high dimensional accuracy.
• The part needs good strength value.
• The part needs good strength value.
• The part needs shorten casting cycle time for high profitability.
• The part needs the specified parameter for the reproducible quality of the components.

 

How Katio works as your reliable custom die casting mold manufacturing and production manufacturer?

On customer R&D stage :

• Provide die casting considerations and options consistent with customer demands to reduce the risk of defective parts through our customer early design stage.
• Prior to the die casting mold build stage, kaito can provide support for the rapid prototyping of aluminum.
• And the zinc part.
• Budget and value-engineering die casting project with costing and effective manufacturing process.
• Help your project with lower cost but high profitability.

Die casting mold design and manufacturing stage:

• Advanced CAE Softwares ensure accuracy for your part design, mold design, and manufacturing.
• For critical quality requirements, we use advanced computer simulation software to do mold flow analysis to avoid casting problems by predicting the metal flow, filling characteristics, and solidification of the material.
• It allows design improvements to be incorporated during the build process, avoids the expense and time lost in changes made after the mold is completed.
• Professional project team monitor dies casting mold processing and sampling through continual communication with certified suppliers and customer weekly actual schedule with pictures update to the customer.

Tips for Design Die-casting Part:

• As cast tolerance as tight as +/- .005″, post-machining available for tighter tolerance applications.
• Standard tolerance of +/- .010″ for the first inch and +/-.002″ each additional inch.
• The typical surface finish of Ra 63-125 micro-inch as cast, post-machining suitable for higher quality surface finishes.
• Min. draft angle = .5 degrees.
• Min. wall thickness = .030″ (Thinner wall thickness possible with alternative processes).

 

If we can help you with your project please call us at 0086-769-82821468 or email sales@kaitomould.com

PLASTIC INJECTION MOLDING FOR THE PRODUCTION OF PRECISION PARTS

Injection molding is the name for a process that is used in plastics processing. It allows the production of parts of different sizes that are precisely matched to the specified dimensions. Our company use state-of-the-art machines and systems for plastic injection molding, which are also designed for high utilization. Injection molding is possible because plastic can be bent when heated. It is also possible to liquefy it. Both variants are used in modern plastics processing.

VERSATILE MATERIAL FOR PLASTICS PROCESSING

Plastic is a material that is used in many different ways. These flexible uses are possible because the properties of the plastic allow it to be used outdoors and indoors. In many companies, plastics have become indispensable. The material can be used in wet areas or outdoors for years. Rain and wetness don’t impact the plastic. Only the colors become lighter over time. They fade in the sun. If the plastic is particularly hard, the surface can become porous over time. This should be borne in mind if plastics are to be manufactured for permanent outdoor use and there is no weather protection. A remedy is to use softer plastic. Direct sunlight makes the softer materials less so

Sustainable Innovative Production – Plastic Injection Molding

Plastic is robust and malleable. The material convinces with a low weight. It can swim over water or be used under water. As an important part of machines and systems, plastic impresses with its versatility. This is not least due to the injection molding process. This process also allows the production of very unusual shapes that deviate from classic symmetry. And there are other positive characteristics. Plastic is available in many different colors.

“We aim to Enrich your business and plastic solutions”

 

The color nuances are helpful when differentiations between individual parts or components have to be made. In some areas, color adjustments to the original are required. This is the case, for example, in dental technology. Dentures, no matter what type, wanted to be anchored in the jaw as inconspicuously as possible. The dentist uses color charts for this because the teeth of humans differ in the smallest color deviations. In plastics processing, it is possible to use the exact color of natural teeth for dentures. In this way, the dentures remain invisible when worn.

INDIVIDUAL ADVICE FOR OUR CUSTOMERS

We offer you comprehensive packages for the production of parts from plastic injection molding. When it comes to injection molding, we give great importance to the precise execution of all work. The accuracy of fit is a guarantee.

We manufacture plastic by injection molding and use materials that meet the requirements for later use without restrictions. Let our company manufacture precision parts for mechanical and plant engineering, for the auto industry or for handicrafts and trades. We offer you individual advice on the possibilities offered by injection molding. The satisfaction of our customers is priority, and so our experienced employees carry out every order in accordance with standards. Remain satisfy and send us your request.

“We would be happy to advise you on the implementation of your innovative ideas, convince you with new shapes and state-of-the-art materials that withstand all criteria such as environmental friendliness, sustainability and extreme stress.”

 

MODERN MANUFACTURING AND IN-DEPTH FIELD KNOWLEDGE

 

support and check your items from the technical draft to later series production.

We are solution developer for large series in the field of plastic injection molding. We support medium-sized companies as well as global players from many industries with a non-ultra-complete package consisting of inspiration, innovation and implementation for more competitive advantage and success.

Our employees develop and manufacture plastic parts for various applications and customers from the construction industry, components for electrotechnical products and plant engineering, chairs & furniture, household and the transport & packaging industry.

If we can help you with your project please call us at 0086-769-82821468 or email sales@kaitomould.com

State of The Art Plastic Injection Molding Services

Mastering the diversity, WE offer everything from a single source: toolmaking and molded part production including all post-processing, surfaces, and assembly. WE are a full-service provider: prototypes, toolmaking, molded parts, surface coatings and assembly production including all-round service. Make use of potential cost reduction potential- let us advise you!

With our modern, precise and flexible plastic injection molding processes, we develop and deliver a wide variety of high-quality precision parts made of different plastics – from prototypes to small series. The starting material for injection molding is a thermoplastic granulate, which is made malleable by a melting process and injected under pressure into an injection mold.

What is plastic injection molding?

The thermoplastic injection molding process is a method for the production of molded parts with large volume using plastic materials. Due to its reliability and flexibility in terms of design options, the injection molding process is used in many industries, including packaging, consumer goods and electronics, vehicle construction, medicine and many more.

 

Advantages of injection

Molding Injection is the most commonly used molding process for processing plastics. Completely molded plastic components with complex geometry and high accuracy can be produced fully automatically in short cycle times using the injection molding process. Post-processing is usually not necessary. The proportionate costs for injection molding tools are relatively high due to their complexity.

Injection molding is, therefore, an extremely economical process for the production of large quantities. Complex surface structures such as grains, patterns or engravings can be integrated directly into the shapes. A very wide range of thermoplastic, thermosetting and elastic is available for the injection molding process Plastic materials with very different properties are available.
Injection molding processes
Several highly specialized injection molding techniques have emerged for the production of sophisticated injection molded parts, in which molded parts are automatically manufactured from more than one plastic component in a partially multi-stage injection molding cycle (multi-component injection molding). Depending on whether hard-soft combinations, multi-color parts, marbling effects or the encapsulation of inserts are required, other composite technologies are used. Special processes for the very different types of plastic, such as liquid silicone injection molding, thermoset or elastomer injection molding, guarantee results of the highest quality.
Capacities
We produce injection molded parts with molded part weights from 0.1 to 4,000 g on injection molding machines with up to 1,300 t clamping force. We combine application expertise for selected industries with a great experience for the following injection molding processes:

1- Thermoplastic injection molding 2- Thermoset injection molding 3- Elastomer injection molding

4- Composite injection molding 5- Interval injection molding 6- Over molding of inserts

The quality of our manufactured parts and the satisfaction of our customers are our top priority!

“Whether large series, small series or prototypes, we always manufacture at fair prices!”

With our NC-controlled injection molding machines and CNC-controlled insertion and removal devices, we also produce large quantities on time and in high-end quality.

A high degree of automation and central material supply via a feed system including integrated color metering devices guarantee an optimal price-performance ratio.

We mainly process technical thermoplastic as well as elastomers and high-performance thermoplastics – both in conventional injection molding and in special areas such as micro-injection molding, thin-wall injection molding and insert / outsert technology.

Because you expect the best

From design to in-house toolmaking to injection molding, we are your partner for sophisticated plastic molded parts. Our common goal: a high-quality plastic product. We advise you in detail in all areas relevant to success: from usable materials, plastic-compatible design, tool construction, production processes, finishing and assembly options to transport-compatible packaging with a comprehensive logistics solution. The close cooperation with selected strategic suppliers ensures reliable and on-time production. Structured project management continuously monitors and improves the manufacturing process from the planning phase to delivery.

WE BUILD ON YOUR REQUIREMENTS

With the production of complicated injection molding tools in our tool shop, we optimally control the production time, costs and quality. With CAD and the latest CNC erosion and milling technology, we can meet the highest customer expectations, from tool design to process-reliable injection molding tools.

We control your project optimally

Fresh thoughts and new ideas need organizational skills. Our project management brings the necessary flexibility and creative joy. Motivated and technically highly competent, we ensure that product ideas are implemented in technologically mature and competitive manufacturing processes.

Have special machines for

+ 2-component injection molding
+ gas internal and
external pressure injection molding (GID / GAD)
+ fully automatic encapsulation
of inserts
We are always working. In flat structures. Around the clock. And cost-conscious.

If we can help you with your project please call us at 0086-769-82821468 or email sales@kaitomould.com