Difference between revisions of "Injection Molding Shop"

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[[file:I3detroit-injectionmoldingshop.jpg|The injection molding shop]]
+
[[file:I3detroit-injectionmoldingshop.jpg|thumb|right|350px|caption blah blah blah|The injection molding shop]]
  
 
== Acknowledgements ==
 
== Acknowledgements ==
* Thanks to ?? for donating two injection molding machines.
+
* Thanks to Michael F. from the Lansing Makers Network for alerting i3 Detroit to the availability of these machines.
* Thanks to ?? for alerting i3Detroit about the availability of these machines.
+
* Thanks to Jim K., Roger S., Nate W., Brian W., (someone please help with this list!) for hauling these unwieldy, messy, heavy machines from an unlit pole-barn in Ionia to our space under a tight deadline.
* Thanks to Jim K., Roger S., Nate W., (someone please help with this list!) for bringing these unwieldy, messy, heavy machines to the space under a tight deadline.
+
  
 
== Shop Safety!  ==
 
== Shop Safety!  ==
  
 +
*Verify safety gates are functional!
 +
*Know how to properly shut down
 +
*Fire extinguishers are located?
 
*Keep shop area clear of debris, spills, and other hazards.  
 
*Keep shop area clear of debris, spills, and other hazards.  
 
*Wear eye protection at all time when using equipment.  
 
*Wear eye protection at all time when using equipment.  
 
*Wear appropriate clothing. Tie long hair back, remove dangling jewelery.
 
*Wear appropriate clothing. Tie long hair back, remove dangling jewelery.
 
 
*Take your time. Accidents happen because someone is in too big of a hurry.  
 
*Take your time. Accidents happen because someone is in too big of a hurry.  
 
*Think about what you are doing. If something seems unsafe, it probably is.
 
*Think about what you are doing. If something seems unsafe, it probably is.
Line 18: Line 19:
  
 
*[[Arburg ALLROUNDER 150]]
 
*[[Arburg ALLROUNDER 150]]
*[[Arburg (Model TBD)]]
+
*[[Arburg C4b]]
  
 
== Consumables ==
 
== Consumables ==
  
 
*[[Injection Molding Shop Consumables]]
 
*[[Injection Molding Shop Consumables]]
 +
** Mold Release
 +
** Resin - [http://www.midwestresins.com http://www.midwestresins.com]
 +
** Clamps
 +
** Nozzles
  
 +
== ToDo List Notes ==
 +
 +
 +
The intention of these ToDo lists is to maintain current answers to several different questions:
 +
* What do we need to do to make these machines a practical tool for our members?
 +
* How can I help with the injection molding project?
 +
* Is the project making good use of the shop space it occupies?
 +
** Is it making progress or is it stuck?
 +
** Does it have the specific resources/expertise it needs?
 +
** Does it have a practical roadmap to reach success? Refer to Dustins flow chart! Currently attached to side of BigBurg (Arburg 150)
 +
 +
 +
What am I promising to do if I put my name in a "Champion" box?
 +
* Keep track of the status of that ToDo item
 +
* Help coordinate work on that ToDo item to avoid duplication of effort
 +
* Do as much (or as little) actual work on that item as your expertise and time allow.
 +
* Most importantly, if it stops being fun, make noise! Fail loudly! If you're not seeing the progress you want to see on your ToDo item, let people know, ask for ideas and help.
  
 
== Injection Molding Shop Infrastructure ToDo List ==
 
== Injection Molding Shop Infrastructure ToDo List ==
Line 31: Line 53:
 
! Description
 
! Description
 
! Status
 
! Status
! Contact
+
! Champion
 
|-
 
|-
 
| Location
 
| Location
 +
| Moved to east shop wall between kiln and paint storage
 +
| Done
 +
|-
 +
| Storage
 +
| assemble pallet rack along east wall, will require grinding,
 +
possible bolts or welding to attach rails
 +
| NateW or ask for vision
 +
|-
 +
| Resin storage:
 +
| Some resin is in bins, some in paper bags, some in jugs.  Regular bins OK for our old resin stock. Acquire more airtight bins/containers/barrels when new resin is purchased.
 +
http://www.imscompany.com/PublicExtra/LP_StorageBins.aspx
 
|  
 
|  
|
+
|-
 +
| Resin management:
 +
| Labels and database for what resin and quantity we have.
 +
| Nate W
 
|-
 
|-
 
| Exhaust system
 
| Exhaust system
|  
+
| Note that what may appear to be a vent pipe with a red funnel is actually a chute for parts to fall down.
 
|
 
|
 
|-
 
|-
 
| Cooling water supply
 
| Cooling water supply
| We do not expect to need a chiller
+
| We do not expect to need a chiller, but we do expect to need open-loop or closed-loop room-temperature water flow.
 
|  
 
|  
 
|-
 
|-
| Electrical power
+
| Compressed air supply for the smaller machine
| 240V 18A 3PH rating on large hydraulic pump motor
+
| Extend a line into the molding shop, tap into overhead lines
Heater power TBD, smaller machine TBD
+
 
|  
 
|  
 
|-
 
|-
| Plastic pellet storage
+
| Electrical power
|  
+
| Overhead pendulum drop, 240V 18A 3PH rating on large hydraulic pump motor, heater power TBD.
 +
Smaller machine is 110V.
 +
| Ted or Dave?
 +
|-
 +
| Hydraulic fluid spill management for the larger machine
 +
| Sheet metal pan under the machine (proposed), automotive oil pan until constructed.
 
|  
 
|  
 
|-
 
|-
| Hydraulic fluid spill management
+
| Wheels/casters for easy relocation of machines
| Sheet metal pan under each machine (proposed)
+
| Small machine needs heavy duty and lockable wheels/casters/skid plates.
 +
The big machine has rubber feet for a reason, user death imminent!
 
|  
 
|  
 
|-
 
|-
 
|}
 
|}
 
  
 
== Injection Molding Shop Support ToDo List ==
 
== Injection Molding Shop Support ToDo List ==
Line 67: Line 107:
 
! Description
 
! Description
 
! Status
 
! Status
! Contact
+
! Champion
 +
|-
 +
| Arburg Documentation
 +
| Arburg C4b manual (photocopy) is stacked on top of the machine.
 +
| Roger S.
 +
|-
 +
| Safety: Oil, resin, people near hot surfaces. Fluids under high pressure. Rapidly closing molds.
 +
|
 +
|
 
|-
 
|-
 
| Mold Design
 
| Mold Design
Line 75: Line 123:
 
|-
 
|-
 
| Mold Fabrication
 
| Mold Fabrication
| Tool steel appears to be impractical.  
+
| Tool steel appears to be impractical for our shop.  
 
Forged/rolled Al plate (specialized mold alloy) proposed.
 
Forged/rolled Al plate (specialized mold alloy) proposed.
 +
Alumold 500 is available from Alro. Expect to get many hundreds of shots with a conservatively-designed mold made from the right aluminum stock.
 
|
 
|
 
|-
 
|-
Line 83: Line 132:
 
|  
 
|  
 
|-
 
|-
|}
+
| Reading List
 +
|
 +
* [http://www.quickparts.com/learningcenter/basicsofinjectionmoldingdesign.aspx Basics of Injection Molding Design]
 +
* [http://www.plasticstoday.com/ Plastics Today]
 +
* [http://books.google.com/books?id=zFZT0acVel4C&printsec=frontcover&source=gbs_ge_summary_r&cad=0#v=onepage&q&f=true Practical Guide to Injection Molding (on Google Books)]
 +
* [http://hyundaidoor.com.vn/images/tailieunghanhcokhi/hngdanveducphun.pdf Practical Guide to Injection Molding]
 +
* [http://www.3ders.org/articles/20130408-making-short-run-injection-molds-with-3d-printing.html Possible idea for easy/inexpensive short run molds]
  
 +
|
 +
|-
 +
| Project plans/status/info on i3 Detroit wiki
 +
| First injection molding wiki page (this page) has been started
 +
| Dave S.
 +
|-
 +
|}
  
 
== Arburg ALLROUNDER 150 ToDo List ==
 
== Arburg ALLROUNDER 150 ToDo List ==
Line 92: Line 154:
 
! Description
 
! Description
 
! Status
 
! Status
! Contact
+
! Champion
 
|-
 
|-
| Documentation
+
| Degrease more
| Attempt to contact Arburg in Germany.
+
| Grab a bucket of warm/hot water, put some purple power in it, wipe grease off machine.  
 +
Don't get water in the oil reservoir
 +
| anyone!!
 +
|-
 +
| Grease machine
 +
| Find grease nipples and make sure they are lubed
 +
| NateW
 +
|-
 +
| Move to new home
 +
| Located between kiln and tool crib on east wall
 +
| Done
 +
|-
 +
| Wire
 +
| Connect the 2 220v lines to the bus bar, rewire from control box to motor.
 +
Ted wants to run a pendulum drop, this would be ok if a 110v outlet is also on this drop for the CB4
 
|
 
|
 
|-
 
|-
|  
+
| Replace key switch
|  
+
| (f00f says he plans to rekey it half of key is stuck in front plate on control box)
 +
Otherwise a lock in place 2 position switch is fine.
 +
|
 +
|-
 +
| Figure out fuses for thermal controls
 +
| (they appear to be missing)
 +
|
 +
|-
 +
| Cooling
 +
| Reservoir and pump, possible 5gal bucket.
 +
|
 +
|-
 +
| Hydraulic fluid
 +
| lost a bit in transit - should be ok at level to test, will need more soon 5-8gal aprox.
 +
|
 +
|-
 +
| Lower barrel to horizontal position
 +
| This can be left in current state for time being, we dont have a mold to run, can be tested without.
 
|  
 
|  
 +
|-
 +
| Test
 +
| with or without mold, there is 1 mold that may work, needs cleaning/repairs
 +
| Nate W.
 +
|-
 +
| Clean up small 6" mold to test
 +
|
 +
|
 
|-
 
|-
 
|}
 
|}
  
 
+
== Arburg C4b ToDo List ==
== Arburg (Model TBD) ToDo List ==
+
  
 
{| cellspacing="1" cellpadding="1" border="1" class "wikitable"  
 
{| cellspacing="1" cellpadding="1" border="1" class "wikitable"  
Line 111: Line 211:
 
! Description
 
! Description
 
! Status
 
! Status
! Contact
+
! Champion
 
|-
 
|-
|  
+
| Degrease more
|  
+
| Grab a bucket of warm/hot water, put some purple power in it, wipe grease off machine.
 +
Don't get water in the oil reservoir
 +
| anyone!!
 +
|-
 +
| Grease machine
 +
| Find grease nipples and make sure they are lubed
 +
| NateW
 +
|-
 +
| Move to new home
 +
| Located between kiln and tool crib on east wall
 +
| Done
 +
|-
 +
| Electrical wires on machine:
 +
| drooping/hanging wires, deteriorating insulation, replace main plug,
 +
no wiring diagram as yet.
 
|
 
|
 
|-
 
|-
 +
| Cooling
 +
| not required
 +
|
 +
|-
 +
| Compressed air supply
 +
| Route line down to machines. Tap off above line if possible.
 +
|
 +
|-
 +
| Solenoids: Not engaging, could be a timer (controls on controller box) issue.
 +
| Wiring is pretty rough, Need to determine if they electrically function.
 
|  
 
|  
|  
+
|-
 +
| Solenoids: Exhaust mufflers
 +
| There are screw caps on the solenoids for caps or exhaust mufflers, most likely mufflers.
 
|  
 
|  
 +
|-
 +
| Thermocouple: Replace!
 +
| Appears it fully failed
 +
| Nate W
 +
|-
 +
| Test
 +
| OMG IT MADE SOME PARTS!!
 +
Tons of work still to go
 +
| Nate W
 
|-
 
|-
 
|}
 
|}
 +
 +
== Project Milestones ==
 +
 +
* First photo of the Injection Molding Shop with machines and supplies in place '''(Done!)'''
 +
* Electrical power supplied, machine turns on '''(C4b Done!)'''
 +
* Working pressure reached in hydraulic circuit with no visible leaks (working pressure reached in compressed air circuit with no audible leaks) '''(C4b Done!)'''
 +
* Cooling water flowing with no visible leaks
 +
* Stable temperature control observed '''(C4b needs new thermocouple !)'''
 +
* Melted plastic supplied to a mold '''(C4b Done!)'''
 +
* First example of molded plastic item using mold from the pole-barn. '''(C4b Done!)'''
 +
* First mold fabricated at i3 Detroit
 +
* First example of molded plastic item using mold fabricated at i3 Detroit

Revision as of 09:43, 30 July 2013

The injection molding shop

Contents

Acknowledgements

  • Thanks to Michael F. from the Lansing Makers Network for alerting i3 Detroit to the availability of these machines.
  • Thanks to Jim K., Roger S., Nate W., Brian W., (someone please help with this list!) for hauling these unwieldy, messy, heavy machines from an unlit pole-barn in Ionia to our space under a tight deadline.

Shop Safety!

  • Verify safety gates are functional!
  • Know how to properly shut down
  • Fire extinguishers are located?
  • Keep shop area clear of debris, spills, and other hazards.
  • Wear eye protection at all time when using equipment.
  • Wear appropriate clothing. Tie long hair back, remove dangling jewelery.
  • Take your time. Accidents happen because someone is in too big of a hurry.
  • Think about what you are doing. If something seems unsafe, it probably is.

Equipment

Consumables

ToDo List Notes

The intention of these ToDo lists is to maintain current answers to several different questions:

  • What do we need to do to make these machines a practical tool for our members?
  • How can I help with the injection molding project?
  • Is the project making good use of the shop space it occupies?
    • Is it making progress or is it stuck?
    • Does it have the specific resources/expertise it needs?
    • Does it have a practical roadmap to reach success? Refer to Dustins flow chart! Currently attached to side of BigBurg (Arburg 150)


What am I promising to do if I put my name in a "Champion" box?

  • Keep track of the status of that ToDo item
  • Help coordinate work on that ToDo item to avoid duplication of effort
  • Do as much (or as little) actual work on that item as your expertise and time allow.
  • Most importantly, if it stops being fun, make noise! Fail loudly! If you're not seeing the progress you want to see on your ToDo item, let people know, ask for ideas and help.

Injection Molding Shop Infrastructure ToDo List

Description Status Champion
Location Moved to east shop wall between kiln and paint storage Done
Storage assemble pallet rack along east wall, will require grinding,

possible bolts or welding to attach rails

NateW or ask for vision
Resin storage: Some resin is in bins, some in paper bags, some in jugs. Regular bins OK for our old resin stock. Acquire more airtight bins/containers/barrels when new resin is purchased.

http://www.imscompany.com/PublicExtra/LP_StorageBins.aspx

Resin management: Labels and database for what resin and quantity we have. Nate W
Exhaust system Note that what may appear to be a vent pipe with a red funnel is actually a chute for parts to fall down.
Cooling water supply We do not expect to need a chiller, but we do expect to need open-loop or closed-loop room-temperature water flow.
Compressed air supply for the smaller machine Extend a line into the molding shop, tap into overhead lines
Electrical power Overhead pendulum drop, 240V 18A 3PH rating on large hydraulic pump motor, heater power TBD.

Smaller machine is 110V.

Ted or Dave?
Hydraulic fluid spill management for the larger machine Sheet metal pan under the machine (proposed), automotive oil pan until constructed.
Wheels/casters for easy relocation of machines Small machine needs heavy duty and lockable wheels/casters/skid plates.

The big machine has rubber feet for a reason, user death imminent!

Injection Molding Shop Support ToDo List

Description Status Champion
Arburg Documentation Arburg C4b manual (photocopy) is stacked on top of the machine. Roger S.
Safety: Oil, resin, people near hot surfaces. Fluids under high pressure. Rapidly closing molds.
Mold Design CAE (software tool chain?)

Copy existing mold design (where to find examples?)

Mold Fabrication Tool steel appears to be impractical for our shop.

Forged/rolled Al plate (specialized mold alloy) proposed. Alumold 500 is available from Alro. Expect to get many hundreds of shots with a conservatively-designed mold made from the right aluminum stock.

Process Control Temperature (two zones), pressure, cycle time, etc.
Reading List
Project plans/status/info on i3 Detroit wiki First injection molding wiki page (this page) has been started Dave S.

Arburg ALLROUNDER 150 ToDo List

Description Status Champion
Degrease more Grab a bucket of warm/hot water, put some purple power in it, wipe grease off machine.

Don't get water in the oil reservoir

anyone!!
Grease machine Find grease nipples and make sure they are lubed NateW
Move to new home Located between kiln and tool crib on east wall Done
Wire Connect the 2 220v lines to the bus bar, rewire from control box to motor.

Ted wants to run a pendulum drop, this would be ok if a 110v outlet is also on this drop for the CB4

Replace key switch (f00f says he plans to rekey it half of key is stuck in front plate on control box)

Otherwise a lock in place 2 position switch is fine.

Figure out fuses for thermal controls (they appear to be missing)
Cooling Reservoir and pump, possible 5gal bucket.
Hydraulic fluid lost a bit in transit - should be ok at level to test, will need more soon 5-8gal aprox.
Lower barrel to horizontal position This can be left in current state for time being, we dont have a mold to run, can be tested without.
Test with or without mold, there is 1 mold that may work, needs cleaning/repairs Nate W.
Clean up small 6" mold to test

Arburg C4b ToDo List

Description Status Champion
Degrease more Grab a bucket of warm/hot water, put some purple power in it, wipe grease off machine.

Don't get water in the oil reservoir

anyone!!
Grease machine Find grease nipples and make sure they are lubed NateW
Move to new home Located between kiln and tool crib on east wall Done
Electrical wires on machine: drooping/hanging wires, deteriorating insulation, replace main plug,

no wiring diagram as yet.

Cooling not required
Compressed air supply Route line down to machines. Tap off above line if possible.
Solenoids: Not engaging, could be a timer (controls on controller box) issue. Wiring is pretty rough, Need to determine if they electrically function.
Solenoids: Exhaust mufflers There are screw caps on the solenoids for caps or exhaust mufflers, most likely mufflers.
Thermocouple: Replace! Appears it fully failed Nate W
Test OMG IT MADE SOME PARTS!!

Tons of work still to go

Nate W

Project Milestones

  • First photo of the Injection Molding Shop with machines and supplies in place (Done!)
  • Electrical power supplied, machine turns on (C4b Done!)
  • Working pressure reached in hydraulic circuit with no visible leaks (working pressure reached in compressed air circuit with no audible leaks) (C4b Done!)
  • Cooling water flowing with no visible leaks
  • Stable temperature control observed (C4b needs new thermocouple !)
  • Melted plastic supplied to a mold (C4b Done!)
  • First example of molded plastic item using mold from the pole-barn. (C4b Done!)
  • First mold fabricated at i3 Detroit
  • First example of molded plastic item using mold fabricated at i3 Detroit