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Custom Molding

Custom molding allows for the creation of parts and products that are precisely suited to the specific requirements of a project. If you want to make your products to be unique, then this is the most suitable way for you. This level of customization ensures optimal performance and functionality. Here’s an overview of the general steps involved in the custom molding process:

1. Design Phase:

According to customer’s initial drawing and request, our R&D team and engineering team will send you 3D drawing like below to check the whole design for approval.

draft drawing from design drawing

2. Material Selection:

Basically, there’s 3 main material commonly used and it’s plastic, stainless steel and silicone. 

Common plastic materials like Nylon, PP, TPR, ABS can be used to manufacture kitchenware depending on requirement and budget.    After testing, it finds out that PA66 Nylon with 30% Fiber is perfect for premium kitchenware and get positive feedback from the customer. Each of these thermoplastic materials has its own unique set of properties and applications, ranging from high strength and durability (nylon, ABS) to flexibility and softness (TPR), catering to diverse industrial and consumer needs. Here’s the feature of them. 

  • Low Friction – doesn’t heat up under high Friction
  • Chemical Resistance – resistant to corrosion from chemicals
  • Abrasion Resistance – useful for elastic and clothing applications

The advantages of nylon PAs include their toughness and high heat resistance. They also have high abrasion resistance, good fatigue resistance, and noise dampening properties. With its low coefficient of Friction, injected molded nylon is suitable for high Friction and wear applications.

Although nylon does not offer inherent flame resistance and can burn quickly, flame retardant versions are available. Similarly, although nylon can be degraded by sunlight, a UV stabilizer can be added to improve performance. In addition, the material offers poor resistance to strong acids and bases. Although it’s a strong plastic, it tends to absorb water. It’s not the ideal choice for marine applications.   

  • Chemical Resistance – doesn’t react with most bases and acids
  • Fatigue Resistance – retains its shape after a lot of bending and flexing
  • Electrical Resistance – strong insulation properties
  • Elasticity – can bend, flex and deform without actually breaking

Polypropylene plastics provide good chemical resistance and retain their shape after torsion or bending. PP also has a high melting point and won’t degrade when exposed to moisture or water. It is also recyclable up to four times. In addition, recycled PP can be combined with other plastic materials. This versatile material is sometimes referred to as the “steel” of plastics since PP can be tailored to so many different uses.

Injection molded polypropylene degrades with UV light and is extremely flammable. At temperatures above 100° C  (212° F), it dissolves into aromatic hydrocarbons such as benzene and toluene, that are harmful to human health. Because it’s difficult to bond, PP is difficult to paint; however, pigments can be added to color the material.

  • Impact Resistance – rubber-like formulations make ABS resilient to impact
  • Surface hardness – high rigidity in certain formulations
  • Uniform Shrinkage – good dimensional stability
  • Machinability – easy to form after cooling

ABS is tough, relatively inexpensive, and provides good resistance to heat, oils, acids, and alkalis. Its styrene content imparts a shiny, attractive finish to injection molded parts, while its butadiene content delivers exceptional toughness, even at low temperatures.

Because ABS lacks strong resistance to sunlight or weather, it’s not a good choice for outdoor applications. ABS also generates significant smoke when it’s burned, provides poor resistance to high Friction, and lacks resistance to solvents such as water. 

  • TPR is a blend of rubber and plastic polymers that combines the properties of both materials.
  • It offers flexibility, resilience, and good grip, similar to traditional rubber, but can be processed using typical thermoplastic techniques such as injection molding.
  • TPR is commonly used in applications where a soft, rubber-like material with the processing ease of thermoplastics is required, such as in grips, seals, footwear, and soft-touch components.

Stainless steel is an iron alloy, containing a minimum of 10.5% chromium. Although grades such as 304 and 430 are popular grades, the term ‘stainless steel’ covers a wide variety of metals, each enhanced with various alloying elements to give specific properties such as increased corrosion resistance or improved strength.
Stainless steel has become very popular due to its relatively low cost, aesthetic appearance, high corrosion resistance and low maintenance.

Grade 304 / 1.4301 (European reference – 1.4301) has good corrosion resistance and good formability. Grade 304 is non-magnetic

Grade 430 (European reference – 1.4016) is a low cost stainless steel. It fabricates well. Grade 430 is magnetic.

3. Tooling and Mold Design:

The main goal of mold design and tooling is to create a product with high manufacturability—a high-quality process that is simple and efficient, long-lasting, easy to operate and maintain, and that meets all customer specifications at the lowest possible cost.

molding design
whole mold made be two half
molding design
molded part

4. Mold Fabrication:

metal mold tube

As a technical and detailed process, mold fabricating typically involves using specialized software tools and equipment to produce a three-dimensional model of the mold or die, machining from a solid block of material using precision machining techniques.

5. Molding Process:

During molding process, it need to use the CNC Machinery to shaping the molded part with precision. Here’s some working picture reference.

molding machinery working
engraving
CNC machinery engraving the mold details
deepen the edge

6. Part Removal and Finishing:

In order to got more precision mold, we will use the red paint to painting the molded half part, then put it together with the lefted part. Then you can find out the unprecise place without red paint mark.

half mold for a turner
back half
another half mold for turner
front half

7. Quality Assurance:

  • Throughout the custom molding process, quality checks and inspections are conducted to verify dimensional accuracy, material integrity, and overall part quality.
  • Defective parts may be discarded or reworked to meet quality standards.

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