Mould Tool, Design and Manufacture Sub-Contract Injection Moulding
Wire and Spark Erosion,
Sub Contract Machining
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Case Studies - Wire and Spark Erosion, Sub Contract Machining

The brief

Customer: Silleck Mouldings Ltd
End user: Motorola
Description: Antenna cap moulding
Polymer type: ABS

Key Customer requirements:-

* High quality finish
* Six sigma requirement (3.4 rejections per million produced components)
* On time delivery
* Optimum cycle times
* Tool longevity with minimal repair

Pascoe Engineering is one of the few mould-makers currently being used by Motorola in Scotland. The antenna cap represents one of several tools recently made for a Motorola cell phone.

This project involved the production of a fluid shaped antenna cap moulding for a new mobile phone. The finished component would need to be highly durable, with a matched finish to the rest of the mobile phone. Silleck Mouldings Ltd and their client Motorola both required optimum cycle times and a tool capable of producing components to meet six sigma standards.

Production Criteria

The antenna cap represents a good example of the true 3 dimensional forms and shapes that have to be produced for today's product designs. Though a small component, the antenna cap would see a lot of stress in everyday use and therefore needed to be produced with the utmost precision. This requirement was further complicated by the problem of producing a core and cavity shut off around a compound curve. It is a tool that other companies have tried and failed to produce to standards achieved by Pascoe.

To guarantee the tool would shut-off effectively around the compound curve, the mould tool was modelled using a variety of complementary software tools. Pascoe Engineering has recently added DelCam Duct stations to produce the required cutter paths, as well as upgrading existing Autocad packages and the purchase of Pro-Engineering Cad stations.

The Process

In order to ensure optimum cycle times and minimal errors, it was decided that the tool would need to be first produced in soft metal for in-house testing and subsequent modification.

Through this process our engineers were able to ensure a proper shut-off and correct forming through the creative use of spark technology. Extra design work was put into guide the ejection system to ensure that the blades were not stressed by the process.

- Customer order
- Tool Design review
- Production of 3-D artworks for customer review
- Design of mould tool in soft metal
- Test of mould tool
- Samples inspected
- Modification of mould tool design
- Re-test
- Consideration and implementation of further changes
- Finalisation of tool layout
- Prototype tool submitted to client for approval
- Production of finished tool in hard metal
- Tool sampling
- Full inspection report on component supplied
- De-bug not required
- Component submission and Customer approval of parts
- Tool sign off: "Ready for Production"