Molding Concepts into Profits

Dip molding is a method to produce a durable, flexible end product at low costs that  meet high precision tolerances. The plastic polymer materials used will depend on your specific product's requirements, but all are very suitable for the production of complex shapes and sizes, and are available in a myriad of colors.

From an aesthetical point of view, dip molding offers added value to products for both industrial and consumer applications. Once your design is converted into metal mandrels (or molds), we can easily produce very small to large production runs on demand.

Design to Production

To mold your concept into a finished product we follow a simple, but comprehensive process. We work with you throughout the development cycle to ensure the final product meets your design and material specifications.

1. Provide the specification, Drawings, or CAD files (we can assist)
2. We submit a quote for your acceptance
3. We develop the prototype mandrel (mold)
4. We test dip molding and provide samples to spec
5. We produce the production mandrels in quantity
6. Proceed to full production

Dip molding process step by step.

Dip Molding Process

1. The mold

To make a special dip molded part, we first have to make a metal mandrel that will form the inside (a negative) of the product. In the prototype stage the first tests will be done and, if needed, adjustments will be made. If the quality of the prototype meets your specifications, a number of production mandrels will be made, depending on the size of the production run required. These mandres will be turned and shaped, or made from an aluminum casting to meet the exact specifications provided.

2. Heating the mold in the oven

The mold will be preheated in an oven to the temperature required to convert the plastic polymer into a solid.

3. The heated mold will be dipped into a  liquid plastic polymer

The mold is attached to a special frame and is dipped in a bath of liquid plastic compound. The heat of the mold and the dipping time determine the thickness of the finished product.  These two variables are adjusted to meet the specifications of the product.

4. Curing of the dipped mold in the oven

The hotter the mold and the longer the dip, the thicker the gelled coating.  During the "cure" in the oven, the plastic compound material fuses to complete the process.

5. Cooling of the dipped mold in water

The mold is briefly dipped in water so the layer can cool down prior to removal from the mandrel.

6. Stripped from the mold

The end product will be removed from the mold manually, or with compressed air.

7. Complete end product

If needed, the product can be cut, punched or printed.

Advantages of Dip Molding

Because we start with one single prototype mold the start-up cost for the development of your new product is much lower. In this stage changes can be made very easily and at minimum cost.  Production molds are based on the size of the production run (small runs = less molds). Because of this the cost per unit remains constant.

1. Low costs for the prototype of the mold

2. Low costs for the production of the mold

3. Small runs at reasonable cost are achievable

4. Short delivery times

5. Alternative colors and finishes (glossy and matt) can be created without new molds

6. A wide range of properties are available such as durometer (hardness), clarity and electrical

7. The molds are stress-free resulting in long service life

 

From prototype through finished product, look to us to provide complete support throughout the development and manufacturing process. To request a Quote, click here, or email us at info@swlatex.com.