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Make a plastic phone cover using CNC milling

This topic contains 45 replies, has 14 voices, and was last updated by  Jerry de Vos 31 minutes ago.

1
Jerry de Vos jerzeek

Make a plastic phone cover using CNC milling

11/11/2017 at 21:32

Hi Guys,
I made an instuction video on how to make this, and in this thread i want to reply on questions that you guys might have!
πŸ˜€

Why not design the injection point on the inside of the phone cover? – by @jegor-m
This is cause the inside has an insert to mold around, and in general you want to prevent injecting through inserts.

Where does the air go
Yes on big injection machines this is a problem, but here the tolerances are not so thight, one scratch and you will have plenty of ventilation…

What material did you use?
The mold is made out of Aluminum

How much did the mold cost?
We paid €400 for the mold, €50 for shipping

Software?
I used Solidworks mainly because i know the program very well and the iPhone can have difficult radii. you can easily use fusion360, thinkercat or any other (free) program, but im still learning those πŸ˜‰

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warrior
27/04/2018 at 10:12
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@manuelmaeder

Don’t worry it’s not the end of the world, small problems like this are fixable, there’s enough metal in the mould to make adjustments.

@jerzeek

Yes, the reworked files look like they line up fine now.

helper
30/04/2018 at 21:24
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i had the same problem at the mould!! i put the one part back to the cnc and i milled that perimetrical line !after that used the mould just with the screws! i thought that was my mistake when i exported the cam thats why i didn’t mention it!

dedicated
01/05/2018 at 09:25
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@manuelmaeder

I still feel bad about this.

Maybe I can help you a bit, it should be possible to change the top halve of the mold in order to fit your bottom halve, then you only need to remake the top halve.
Would you be interested in this?

Greetz, Jerry

warrior
01/05/2018 at 12:55
2

@jerzeek

It’s not necessary to remake half of the mould, it’s possible to just remove the lip, drill holes for dowel pins to correctly align the two halves, and enlarge the clamping holes so they line up.

I’ve already suggested this fix to Manuel and he knows somebody who can do this for him.

dedicated
02/05/2018 at 15:09
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@andyn,

Even better!

starter
13/05/2018 at 20:51
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@jerzeek

It all worked very good i milled the lip away and know it fits with bigger holes for the screws.

So we tried to inject PP in the mold but also with me (84 kg) hanging on the lever arm it only injects as much as you can see on the picture.
What would you suggest me to do ? I think the temperature looks pretty good while injecting its at 260 deg. πŸ™‚

And my second question is about the stamps you have created πŸ™‚ We`d like to make our own stamps with an other logo πŸ™‚ where did you let them produce? It would be great if you could tell me a bit about making those stamps πŸ™‚

greets Manuel.

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warrior
14/05/2018 at 08:44
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@manuelmaeder,

One suggestion would be to may be increase the mould temperature, to have plastic to cool slightly slower.
Another thing: how do you know the temperature of plastic? Could you may be share a photo / sketch of the orientation of the heating elements + the thermocouple location. It could be that your reading is taken from the heating element and that doesn’t represent actual plastic temp.

helper
14/05/2018 at 21:33
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@manuelmaeder Try to use another type of pp , tryΒ  also lpde and i believe for cases is the best!

dedicated
20/05/2018 at 00:42
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@manuelmaeder
Hi
Did you try with ldpe or by warming the mould?
Pictures of the whole installation?
Thanks for the sharing
Precious regards
DiB

starter
21/05/2018 at 22:08
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@jerzeek Hey Jerry πŸ™‚ everything works great with the mold. We want to accelerate our process and therefore we d like to Know what that you used for clamping the mold halfs from the fish mold. It looks like 50 Times faster than using screws for mounting the mold halfs together πŸ™‚ i hope you know what i mean πŸ™‚

helper
21/05/2018 at 22:12
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Hi @manuelmaeder,
I’m not sure if this is what you’re after but have a look at this topic: https://davehakkens.nl/community/forums/topic/injection-mold-quick-release/

warrior
22/05/2018 at 12:51
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@manuelmaeder

 

They look like over-centre toggle clamps, like this.

They are quick but do stretch/give a little under pressure, so you might get more flash along the mould parting line.

warrior
22/05/2018 at 12:56
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@siemenc

Yes, those ones look much more heavy duty, probably better for a larger mould.

starter
22/05/2018 at 17:02
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Thanks for all your answers πŸ™‚ yes thats what im looking for

dedicated
23/05/2018 at 17:52
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Hi guys!

@manuelmaeder, glad to hear that it’s working! just like the the others i would suggest warming the mold, more pressure, hotter plastic, bigger sprue.

On the part of the clamping, indeed these clamps make the process much faster! But make sure you buy decent ones. The cheap one’s bend easily. also @kunststoffschmiedeΒ made moulds with quick releases : here

πŸ™‚

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