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the mill Currently we have an aluminium die that is machined to take a 5" x 3" x 3/8" inserts in either half of the mold. This gives (roughly) a maximum part dimension of 4" x 2" x 1/2". For moldings larger than this it will be necessary to order an Aluminum blank from Minijector. |
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run g-code Using the facing tool for the mill, face the aluminum inserts to give a flat, smooth, surface finish. Cut pieces to 5" x 3", then run your g-code to make a negative of the piece to be molded. Here, the molded piece is being cut with a 3/8" flat bit. |
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flow channels It is now time to mill your flow channels. Note that there is an over-run at the end of each line to accept the cold 'nose' of incoming polymer. This ensures that hot flowing polymer enters your mold. At left is the milling recess at the opposite end of the mold. |
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flow channels For an extra good finish and to ensure alignment of your molds it is a good idea to place alignment pins. Two in opposite corners should be enough. A press fit stud in one side of the mold and a neat fitting hole on the other side are perfect. |
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finishes & finished Note that the surface finish of your mold determines the surface finish of your part. If you desire a smooth finish hand polishing of the surfaces is possible. Sandblasting and other techniques can be used to give textured finishes. |
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