KASO PLASTICS MOLD BUILD STANDARDS

UNCONTROLLED COPY

KASO PLASTICS MOLD BUILD STANDARDS

KASO Plastics Incorporated 5720-C N.E.121st Ave Suite 110

Vancouver, WA 98682

MARCH 31, 2017

APPROVED BY: _________________________________________

UNCONTROLLED COPY DATE: 03/31/2017 Page 2

GENERAL OVERVIEW This guideline is provided to our suppliers as a guideline for what we at KASO Plastics Incorporated have determined to be our minimum design and build requirements for injection molds that are procured through us. The tool-maker should refer to this information as a guideline during the design process. It is our hope that the information will be used to form a sound base for the entire mold design and that our supplier can then add their valuable input to produce a superior concept, manufacturable design, and ultimately an excellent mold that not only is of superior quality, but produces quality product within our specified parameters. As KASO Plastics prides itself on being a value added supplier, we expect and encourage all of our suppliers to provide input on all aspects of the design and construction of our injection molds. Any and all suggestions that will positively affect the quality of construction, quality of molded parts, tool longevity, cycle time, overall cost, and lead-time are welcomed and KASO Engineering will actively explore all suggestions.


Table of Contents

Section

General Overview

Quote, Design, and Tool Build Standard

Mold Classifications

Mold Bases

Parting Line Locks

Cavity and Core Specifications

Side Actions and Lifts

Runner and Gate Systems

Ejector System

Cooling System

Shipping

Tooling Terms and Conditions

2

4 6 7

10

16

18

21

25

28

29

30


KASO PLASTICS INC. QUOTE, DESIGN, AND TOOL BUILD STANDARD

This standard is to be used as a guideline for our suppliers so they can familiarize themselves with our process as they relate to tool construction from the initial quote to final delivery of the mold. If there are any issues that need clarification by any of our suppliers, they are strongly encouraged to contact KASO Engineering to seek clarification.

1. Tool quotation a. KASO will provide our Mold Specification Form similar to the SPI

Standard Form or a detailed description of the tooling requirements and any other information we have to approve suppliers for their consideration.

b. KASO asks that all suppliers make every effort to return their quotations to us no later than 2 working days after receipt of the RFQ.

2. Award of tooling

a. When KASO is awarded a project, the Engineering Department will then contact the appropriate supplier and confirm the price and lead-time. Once confirmed the specific shop will be contracted to complete the specified tooling.

b. It is worth noting that KASO Plastics does not specifically look at price as a deciding factor when sourcing tooling. Though price is a factor, we also consider many factors in the final decision. These factors include but are not limited to quality, on-time delivery, location, past and present working relationship, and the specific capabilities of each shop.

3. Preliminary design review

a. KASO will reaffirm the P.O., data, material, and mold shrinkage on our “Authorization to Design, Order and Fabricate” form. Once issued, KASO expects the chosen tool shop to begin the design process based on the tooling standards provided herein as soon as possible.

b. KASO requires tooling vendors to provide a 3-D design for all molds they are awarded.

1. 2-D layouts are acceptable for preliminary layouts c. We will then review the design internally and if necessary schedule a

design review with a representative of the tool shop. d. The design will be reviewed for functionality and to ensure it meets all

applicable KASO requirements.


4. Final design review

a. Once it is confirmed that the design meets all requirements and any changes that were discussed in the preliminary design review have been made, the supplier will then be given Authorization to Design, Order and Fabricate.

b. Once this authorization has been received by the tool-maker, building of the tool may proceed.

c. If requested, the supplier will provide a detailed schedule at this time that accurately maps out all important dates.

5. Tool Build a. The schedule provided after the final design is approved will need to be

updated weekly throughout the length of the tool build. b. KASO Engineering must be informed as soon as possible of any major

issue that will affect the schedule. c. Please do not hesitate to contact our engineers with an update if there is

pertinent information that will affect the schedule. Nothing is worse than being late and us finding out the day before the tool is due!

6. Shipping

a. Shipping is considered FOB KASO. If otherwise, please specify so we can make any necessary arrangements.

b. Please immediately notify us of a tool shipment destined for our plant; also provide us with tracking information.


KASO PLASTICS INC. MOLD CLASSIFICATIONS Class 101 – Capable of 1 million + cycles, this is a precision high production tool and is designed and constructed with this purpose in mind. Mold base is minimum 280BHN (Rc30). All cavities, cores and other molding surfaces, hardened to a minimum of Rc 50 and, where possible, have hardened wear plating. All other details such as slides, heel block, gibs, wedge blocks, etc., should also be of hardened tool steels. Any lift action shall be hardened and TiN coated. Part ejection shall be guided. All slides are required to have replaceable hardened or Lamina wear plates. Electroless nickel plating of all mold plates with water channels is recommended to inhibit rust. Side parting line locks are required. When possible, the gate should be hardened and replaceable. Where feasible, multiple cavity tools should be designed with as few cavities per insert as possible (preferably 1). Class 102 – Capable of up to 1 million cycles, this tool should be considered a medium to high production tool. This mold is identical to a class 101 with the following items not required: hardened or Lamina wear plates, nickel plated mold plates, gate inserts, and where applicable, tapered parting line locks may be substituted for side style. Although these items are not required, they may be added if the tooling necessitates. Class 103 – Capable of less than 500,000 cycles, this mold is considered a medium production mold. Mold base is to be a minimum of 165 BHN (15-17RC). Cavities and cores to be a minimum of 280 BHN (30RC). Guided ejection is required. Other options may be added where required. Class 104 – Capable of less than 100,000 cycles, this is a low production mold. Cavities can be of pre-hardened tool steel or other specified material. All additional features are optional. Class 105 – Capable of very limited production, this mold should not be expected to run more than 500-1000 cycles. The entire mold may be produced of aluminum or other specified material with sufficient strength to produce the required amount of parts. This tool should be considered prototype only. Only the very basic mold components are used and anything additional should be considered optional. Note: These classifications go beyond the current SPI standards. Please review them carefully.


MOLD BASES

• Break all sharp edges on all plates with either 1/16 chamfer or radius • Pry slots on center or corners of parting line and between all doweled or

pinned plates

Figure 1: Diagram of edges of the mold with 1/16” chamfer or radius and the pry slots.

Pry slots on parting line and all doweled

plates should be wide enough to

accept a standard pry bar

Break all sharp edges with 1.5mm radius or chamfer


MOLD BASES

• 3.990” diameter on all locating rings o Locking style whenever possible (DME #6504)

Figure 2: Diagram of location ring with a diameter of 3.990” and lock feature.

LOCK FEATURE


MOLD BASES • Sprue seats to be ½” radius EXCEPT MUD BASES which are to be flat

o Seats need to be hardened minimum 280 BHN (30RC)

Figure 3 and 4: Figure 3 (Top) is a diagram showing the sprue seat and material hardness. Figure 4 (Bottom) show a flat sprue.

Flat sprue on MUD bases. No seat

unless specified by KASO.

.500rad. sprue seat. Material hardness

minimum 280 BHN


PARTING LINE LOCK • Eye bolts on all molds and individual plates over 50lbs.

o At least 1 eye bolt on the top surface needs to be on balanced center of entire tool

• Parting line safety strap of appropriate size for the mold is required on each tool

Figure 5 and 6: Parting line straps of appropriate size are required.

Parting Line safety strap with eye bolt on

Optional Parting Line safety strap


• Early return if required to be DME or HASCO only

Figure 7 and 8: Use only DME and Hasco for early return.

Preferred early return setup


• Allow adequate opening of molds to provide clearance for both runners

and parts to fall free o Critical on 3-plate molds

Figure 9: Provide enough room for Sprues or Runners to drop during ejection.

Allow adequate clearance between the A-plate and stripper plate to allow the runner and gate drops to fall free from the mold

upon ejection


• Locate water in positions where it does not interfere with the clamping of the mold and or other components

• Molds shall have a sufficient amount of support pillars and stop buttons to adequately support the tool as well as the ejector system

Figure 10: The mold must have an adequate number of pillars and stop buttons for support.

Assure the mold is supported by an adequate number of pillars and stop buttons.


• Leader pins to be of proportionate size to moldbase to assure no deflection and MUST extend past any standing feature on the cavity or core by no less than the pin diameter

Figure 11: Leader pins must be sufficient.

• Mold base to be stamped with a minimum of customer name (NOT KASO

PLASTICS), part name and number, and weight o To be stamped on top side

Leader Pins to be of sufficient

size to match the base and extend

beyond any standing steel.


PARTING LINE LOCKS Straight style interlocks on all sides of molds with steel passes or seal-offs

o Certain sides may not need locks depending on the design; Kaso Engineering to authorize

Tapered interlocks can be substituted on tools with no bypasses or similar shot-offs

Bullet nose dowels acceptable on low production and prototype tools Wherever possible locks should be on center of the tool to allow for

thermal expansion without binding

Figure 12: Example of parting line locks.


CAVITY AND CORE SPECIFICATIONS Engrave all steel with type and hardness including all sub-inserted

components

Figure 13: Inserts and other moving components need to be marked with steel type and hardness.

All inserts and other moving components

need to be marked with steel type and hardness.


On multiple cavity tools or where any identical component is used, all parts and their respective locations to be numbered individually

All multiple cavity tools to have cavity ID clearly marked in an area approved by KASO Engineering

Cavities and cores to be .002-.005” above parting line of moldbase Place eye bolt and jack screw holes in corners of all cavity and cores that

weigh in excess of 100 lbs. All ejector pins holes to have a minimum of 3/8” land or 1.5 times the pin

diameter, which ever is greater Vent all cavities as directed by KASO following a design review All designs, programs, electrodes, and any special jigs or fixturing to be

the property of KASO Plastics Any welding MUST be approved by KASO Engineering in writing. Any

welded component will still be required to last the equivalent lifespan of the original non-welded part

Plating of any kind MUST be approved by KASO Engineering


SIDE ACTIONS AND LIFTS Engrave all slides and other moving components with steel type and

hardness including all sub-inserted components Where multiple slides or lifts are used, all parts and their respective

locations to be numbered individually All moving components to have grease grooves

Figure 14: Moving parts must be labeled appropriately and have grease grooves.

Identify part and location where

identical parts are used.

Grease grooves required on all

moving components.

Material callout required.


No guide pin or lift to run at an angle greater than 30 degrees

Figure 15: Angle pins or lifters should not exceed 30 degrees.

Appropriate retainers are required to hold slides in the open position Slides and other moving components to have a minimum of 5 points

Rockwell difference and preferably be constructed of differing material than the stationary areas in which they ride

All Hydraulic or air operated actions that support molding pressure MUST be positively locked and/or of sufficient size to hold cavity pressure during the molding cycle.

o 1500psi available line pressure / 10,000psi cavity pressure


All hydraulic or air operated actions to have industrial quality limit switches installed and be protected from damage

All Hydraulic cylinders to have ANV-38 fittings installed by the tool-maker

Figure 16: Only high quality limit switches are to be used. Use ANV-38 male and female hydraulic fittings.

ANV-38 male and female

hydraulic fittings

High quality limit

switches


RUNNER AND GATE SYSTEMS

All gate and runner styles and sizes will be specified by KASO

Engineering Runner shut-offs accessible from the parting-line required on all family

molds

Figure 17: Runner shut-offs are required on all family molds.

Runner shutoff required on all family molds


Cold slug well required at runner end and at directional changes All runners to be well polished and all corners at directional changes to be

generously radiused

Figure 18: Runner systems should follow the description in the figure.

Sprue pullers required Hot manifold system (where applicable) manufacturer, type, and gate

configuration will be specified by KASO.

Polish entire runner system

Cold slug wells required at runner

end and at directional changes

Radius all transitions and

sharp edges


All junction boxes and connectors to be mounted on the top of the mold whenever possible

Figure 19: Junction box mountings should be done on top of the mold whenever possible.

Mount junction boxes on top of mold whenever

possible


All wiring will be protected and secured in channels, not exposed.

Figure 20: All wires are to be secured in protective channels. A complete wiring diagram is REQUIRED on all tools that have a hot

manifold system installed

All wires are to be secured in

protected channels


EJECTOR SYSTEM

Typical core side ejection is preferred whenever possible

o Any special ejection shall be specified and/or approved by KASO Engineering

The ejector pattern shall have enough surface area to positively remove the part with no distortion

All ejector systems will have enough stroke to fully remove the part from the tool

Figure 21: Parts to have an adequate number of ejector pins and enough stroke to remove parts.

Ejector pins smaller than .0625” and their location shall be approved by KASO Engineering

Standard size DME or similar ejector pins are required

All molds to have adequate amount of

ejector pins and sufficient amount of stroke to remove the

parts.


All ejector pins as well as their respective location shall be clearly marked on the head and in the ejector plate

Contoured ejector pins shall be timed to prevent rotation

Figure 22: Ejector pin marking, locations and timings.

All ejector pins to be proud from insert surface .000-.003”

Clearly mark all pins and their

respective locations

Time all pins that are contoured.


All angled lifts to be RECESSED a minimum of .003” to prevent scuffing during movement

Figure 23 and 24: Lifters should be RECESSED a minimum of .003” to prevent scuffing.

Guided ejection systems where required shall be installed in a balanced manner between the support and box clamp plate


COOLING SYSTEM

Recessed water fittings in 1” diameter counterbores are required whenever possible to assure easy coupling and the fittings do not protrude from the mold plate surface

Water lines are to be of DME Jiffy type 252 unless otherwise specified by KASO Engineering

Use standard 7/16 diameter water lines wherever possible and drill through to facilitate cleaning

Stamp all water circuits with “IN” and “OUT” and number accordingly whenever there are multiple circuits

Figure 25: Water line fittings and markings.

Cool all guided plates as well as stripper and runner plates on 3-plate

mold applications Step round cavities for easy installation of O-rings All baffles to be of brass construction and a minimum or 3/32 thick (NO

PLASTIC BAFFLES) Insulator plates required on molds with hot sprues or that will run oil

Recess water fittings in 1” counterbores

Jiffy type 252 hose connections

Stamp “IN” and “OUT” on all

water lines


SHIPPING

Blow out all cooling lines and generously spray the cavity, core, parting-line, and outside surfaces of the mold with an approved protectant prior to further preparation

Make sure the mold parting-line is completely closed and the safety strap is in place

Encase the tool in a poly bag prior to crating Ensure that the tool is securely attached to a base plate that has

provisions for forklift handling Securely package mold in a wooden crate that has been steel banded

for added protection


5720-C NE 121st Ave, Suite 110 Vancouver, WA 98682

Attachment A – Tooling Terms and Conditions AUTHORIZATION TO DESIGN, ORDER, AND FABRICATE (Form #2.3.200) This form is supplied by our Engineering Department and will be revised at appropriate milestones during the mold build. In addition to referencing the customer name, part name, and part identification (I.D.), it is the controlling document that specifically identifies the database that is to be used at release, the part material, and the mold shrinkage. We will indicate the phase of the build that is authorized (i.e.: design, order materials, fabricate). If at any time our failure to approve the progression of the mold build jeopardizes the committed delivery, we should be notified in writing (fax or email) immediately. MOLD SPECIFICATIONS Mold specifications will be defined on a form that is similar to the SPI standard form or by a detailed description and is typically sent with a Request For Quote (RFQ). Be advised that the final mold specification form that is furnished by our Engineering Department may contain changes from the original quote specification. Contact us immediately if the requirements are unclear or not as agreed. MODIFICATIONS, CHANGES, ALTERATIONS, VARIATIONS Any request for modification(s), change(s), alteration(s), or variation(s) that affect price or delivery must be confirmed to you on a Purchase Order/Change Order. COMPLETED PURCHASE ORDER The tooling shall be considered complete, and therefore delivered, when either the sample parts are delivered, or tool is delivered per the attached Purchase Order, along with the appropriate inspection report.

6.190 Form approved by:_______________________________________________________________ Date:01/31/2013

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