PROJECT – Fabricate low-volume tooling and deliver 30 overmold parts to client for testing using the same material that will be used in eventual high-volume production tooling.

Injection Molding is one of the important process in rapid prototyping. There are many kinds of injection molding: PIM (Plastic Injection Molding), MIM (Metal Injection Molding) and GIM (Glass Injection Molding). However, the most common process we use is Plastic Injection Molding to make Plastic Products.

3D printing, also called additive manufacturing, is a family of processes that produces objects by adding material in layers that correspond to successive cross-sections of a 3D model. Plastics and metal alloys are the most commonly used materials for 3D printing, but it can work on nearly anything—from concrete to living tissue.

Anodizing is a method for changing the surface chemistry of metals and other substrates. It protects against corrosion, enhances aesthetic qualities, resists scratching and is one of the most durable surface finishes available. Anodizing can be done on a range of materials, but today let’s look at aluminum. These 8 questions will help to show why anodizing is a clever surface treatment that’s both practical and beautiful.

Every day our team at Star Rapid receives a large number of 3D CAD files for new ideas and inventions. They arrive in different shapes, sizes and levels of complexity depending on what the customer needs made. But sometimes we’re unable to get to work straightaway for a couple of reasons.

By tracing the history of these innovations we can follow the trends that led to the development of the first numerically controlled machines in the late 1940s and ultimately to the precise, high-speed multi-axis machining centers that we now use everyday for rapid prototyping and low-volume manufacturing.

What is G-Code? G-code is a generic term for a programming language used to instruct a numerically-controlled machine tool. It controls all aspects of machine movement including spindle speed, the tool path, how fast to move and where to locate itself in a multi-axis space.

A common misconception about 3D printing is that you can use the same CAD design for either plastic or metal. In reality, the processes are very different so design changes will be required. The type of modifications needed will depend on the type of metal 3D printing process being used. We will focus on powder bed fusion, which is what we use at Star Rapid.

Plastic injection molding accounts for about 80% of the durable plastic items we find every day. Injection molding uses a mold or die made from aluminum or steel. The mold consists of a core side and a cavity side that is placed into a plastic injection molding machine. This machine heats the raw plastic resin pellets until they’re molten, injects them into the empty cavity of the mold under great pressure, and then opens to eject the finished part.

Getting the best results from plastic injection molding requires that the process control engineer carefully balances several related variables when setting up the machine. One of these variables is clamping pressure.

One of the most important aspects of any product development project using plastic injection molding is choosing the right material, as it directly affects the molding operation and also the part performance. There are thousands of plastic materials available in the market. So, how do you make sure you select the right one?

There are many types of pressure involved when making a plastic injection molded part. We’ve explained the importance of clamping pressure, so now let’s look at injection, holding and back pressure. It’s important for a product developer to understand how these forces work together and ultimately how balancing these forces affects part quality, pieces per hour and your product cost.