Case StudyProduct Development/Production Tooling for an Industrial Application

Industrial ApplicationChallenging our Engineering Prowess

A call to assist in the development of a low pressure application, with interchangeable inserts was received from a company supporting the needs of scaffold and catwalk safety gates. A built-in self-closing safety feature required a compound angled hinge to pivot on a pin mounted to a stationary post. A supplied product design required a feasibility study for parting line runoffs and hinge function.  After product approval the task of building a low pressure mold was at hand. We were challenged with not only the fitting of multiple inserts, compound angled hydraulics, a high polish surface finish and parting line shutoff to prevent leaking into the cylinders but tooling was required to be constructed on a specific angle to allow the flow of material to fill completely without any porosity.

Engineering Resolution

Midwest Mold began our efforts revising the product design and all the parting lines due to the angle of mold design required. All lettering required draft alterations consisting basically of a re-design.  At the same time 3 part designs were to be incorporated into one tool. This required interchangeable inserts in the mold and made accessible so they could be changed from the parting line in the machine for just in time deliveries when required. The initial design phase focused on the parting lines and shutoff to prevent as much leakage as possible. Our NC capabilities help provide a flat shutoff ensuring a leak proof parting line.

Through joint efforts, the correct axis’s for automatic closing of the gate in the installed position without the use of electrical assistance, motorized or air assisted components was developed and designed in. Numerous iterations were presented for approval before finally settling on a product that satisfied our customer and the end user.

Finally, a high polish was applied to both the cavity and core to aid in release and flow of the material.

Engineering Resolution

Upon completion of the mold, samples were produce and leak testing was performed on the floor at Midwest Mold. Using approximately 3 gallons of a urethane material similar to the spec material, the mold was filled on our floor and allowed to cure overnight. The part was de-molded, inspected and sent to the customer for measurement and testing. After the results were received, the mold was created up and shipped south for a very successful first run in plant conditions.