The following is the answer to the question "What challenges does the complex geometry of the product bring to Injection Mold Design":
1. Increased demolding difficulty
When a product has a complex geometry, the first challenge is demolding. Complex shapes often mean more concave and convex structures, curved surfaces and corners. This makes the design of the demolding mechanism of the mold extremely critical. During the design process, the demolding angle and demolding force need to be accurately calculated to ensure that the product will not be damaged during the demolding process. For example, for products with deep cavities or undercut structures, special sliders, inclined tops and other mechanisms may need to be designed, which not only increases the complexity of the mold structure, but also puts higher requirements on the processing accuracy and assembly accuracy of the mold.
2. Complex runner design
During the injection molding process of products with complex geometries, the flow path of the plastic melt also becomes more complicated. In order to ensure that the plastic can be evenly filled into various parts, the design of the runner system needs to be more refined. Reasonable runner layout can reduce the occurrence of defects such as weld marks and cavitation. At the same time, for products with large differences in wall thickness in different parts, it is also necessary to consider how to balance the flow rate of the melt to avoid local over-pressure or under-injection. This requires mold designers to have rich experience and professional knowledge of fluid mechanics to optimize the flow channel design.
3. Difficult mold processing
The injection molds corresponding to products with complex geometric shapes usually have complex cavity and core structures. This poses a great challenge to mold processing. High-precision CNC machining equipment is indispensable, but even so, for some extremely complex shapes, special processing methods such as EDM and wire cutting may be required. These processing methods are not only costly, but also have long processing cycles. In addition, mold assembly has become more difficult, requiring a higher level of technical skills and patience.
4. Increased mold cost and maintenance cost
Due to the above challenges, the cost of injection molds for products with complex geometric shapes is often high. From the complex structure design in the design stage to the high-precision requirements in the processing stage, to the later maintenance and care, more resources need to be invested. Moreover, during the production process, if there is a problem with the mold, the difficulty of repair will increase accordingly. This requires full consideration of the reliability and maintainability of the mold in the design stage to reduce the cost and risk in the later stage.
