Engineering Support
Introduction
Selecting a molding company can be a risky decision. With so many things that can go wrong, the wise customer chooses a molder knowledgeable in plastic materials, advanced mold designs and materials, scientific molding processes, three-dimensional solid modeling with CAD/CAM capabilities, and maintains state of the art quality assurance including high-tech inspection equipment and application of statistical process controls. But most importantly, the wise customer chooses a molder who communicates actively, openly, and frequently with the customer throughout the process.
At Guttenberg Industries, we provide all of this and more. Before the tool design is even complete, our engineers work with your engineers to review the part design for possible material savings, cycle time savings, and quality improvement. We advocate and apply Society for Plastics Industry (SPI) guidelines and standards for Mold Classes, Mold finish, Cosmetic Inspection, and Dimensional Tolerances. Once the project is launched we handle it all. We coordinate the tool build and offer weekly progress updates upon request. We work with your engineers and quality professionals to ensure we understand your unique quality requirements before the mold is even complete. When the mold is complete we sample the mold to verify it meets your requirements and tweak the mold or process until it does. We develop and document statistically proven production processes and control those processes into production. We submit samples and statistical analysis for your approval prior to launching production. All is published in AIAG format upon request including full PPAP documentation. And if you are transferring a tool from another molder, we still do all of the same except for the tool build. Why not let us be an extension of your product development team?
Design Suggestions
Otherwise, a more detailed analysis is performed by a team of experts during the early hours of product launch. This team actively searches for cost saving opportunities and design features that might create a risk of problems later in the process. MoldFlow™ simulation software is used to detect potential problems, maximizing the potential for first-round success. Any ideas are communicated to you right away so that you may update the design quickly if you decide to do so. And if you don’t choose to act on our suggestions, that is fine. But we will keep trying to help in any way we can.
Mold Design Review
Tool designs are developed by toolmakers based on the CAD models provided by Guttenberg Industries on the behalf of you, the customer. Before any actual tool work is begun, the tool design must be approved by Guttenberg Industries. Improper tool design can lead to quality problems, increased production costs, and limited tool life. To minimize the risk, our team of experts reviews each tool design with a point checklist, ensuring the highest quality tool for your money.
Process Development and Control
Excellent product quality begins with a great tool and a robust, repeatable process. During pre-production sampling we validate the tool, but we also develop robust, repeatable processes using scientific injection molding methodologies. Scientific molding is a proven methodology for breaking the molding process into multiple distinct stages, and assembling the best combination of each stage for the best possible outcome. Application of scientific injection molding methodologies ensures a clear distinction between mold problems and processing challenges, but also serves as a basis for future statistical process control.
Capability Studies and Sample Submission
When the mold is sampled and a process is developed, representative samples are evaluated to validate both the tool and the process. A layout is performed detailing actual measurements for each dimension stated on the print you provide, while capability studies are performed on at least 30 pieces to validate statistical capability of Cpk 1.33 or greater (if specified by the customer). When all of the above criteria are met, samples and data are provided to you, the customer.
Production Approval
When your team is satisfied that all of your specifications are met and certain that the results are repeatable, we will submit sample parts and all of the measurement data to you for approval. If you are satisfied with the results, simply provide your approval and we are immediately ready for production. If not, simply discuss the issue with our team and we will resolve the problem promptly.
Product Development Lead Time
Time to market is critical today. The quicker you can get your product into the market the quicker you can begin earning returns on your investments. At Guttenberg Industries we understand this and continually strive to help you minimize this duration. Rapid prototype services are used where appropriate and quick turn-around tooling is often available upon request. Please let us know if this is something that you are interested in pursuing.
Solid Model CAD
At Guttenberg Industries, we use SolidWorks™ 3D Solid Model CAD systems. Below are the most commonly used file formats, although more are available.
* Please send 2D documentation in one of the following formats:
.pdf, .prt (Cadkey), .dxf, .dwg, or .iges (Title block exploded into entities)
* Please send 3D CAD files using one of the following formats:
.stl (typically used in the quoting phase, and cannot be used in mold construction)
.igs (used for mold construction)
.stp (used for mold construction)
