Case studies

Lower & Upper Air Box

Challenge

The mandate was to produce a part with a limited budget and a high probability of significant part warping and unbalanced filling. The design of the part in a very confined environment was described as unsustainable in terms of mold design by several experts in the mold making industry.

Results

We produced the mold in TIBO Asia using a detailed and proactive DFMEA, and analyzing the flow injection mold, which allowed us to minimize warping and achieve injection balance required in the customer's specifications. The design of the mechanism was impeccable, which allowed us to respect customer's complex part design integrity.

Solution

  • Part material (resin): PP 30% GF
  • Part nominal thickness: 0.118"
  • Part weight: 448g + 784g
  • Surface finish cavity, Core: SPI-C3, SPI-C3
  • Press: 725T
  • Annual forecast: 50,000 units
  • Mold type: prototype plastic injection mold
  • Manufacturing location: TIBO Asia
  • Number of cavities: 1 + 1
  • Cycle time: 60 seconds
  • Steel type: Equivalent P20H (32-35 HRC)
  • Injection type: hot tips
  • Extraction/Ejection: hydraulic
  • Mechanism description: 3 hydraulic slides, 2 mechanical slides & 1 lifter
  • Size of mold (inches): 37" x 36" x 35"
  • Mold weight (pds): 9,176

80 Liters Compost Bin

Challenge

We needed to provide a mold to create this high volume and fast cycle-time part despite an unconventional part design and requiring very complex mechanisms in a confined environment.

Results

We created a simple, but very innovative mechanism with optimized cooling to obtain a 53-second cycle time for a nearly 7 pound shot size product.

Solution

  • Part material (resin): HDPE
  • Part nominal thickness: 0.133"
  • Part weight: 3.15kg
  • Surface finish cavity, core: SPI B3 and Sandblast / SPI-C3
  • Press: 2,600 T
  • Mold type: production plastic injection mold
  • Manufacturing location: TIBO Canada
  • Number of cavities: 1
  • Cycle time: 53 seconds
  • Steel type: P20 and P20HH (32-35 HRC) and Aluminium QC-10
  • Injection type: 1 Hot Sprue
  • Extraction/Ejection: Hydraulic Core Stripper Ring hydraulique with air poppet
  • Mechanism description: Cavity: 4 hydraulic mechanisms + 18 inserts + 1 gate cooling insert/ Core: 1 hydraulic mechanism + 4 hydraulic cylinders + 4 inserts
  • Size of mold (inches): 73" X 80" X 58"
  • Mold weight (pds): 38,500

Rear Shelf Centered Head Mounted Shelf Light

Challenge

We had to produce a large part with integrated speaker grills which are generally molded separately and considered non-compliant in terms of injection process, and we had to consider the injection parameters required to produce a large shelf within specifications.

Results

We injected, filled, packed and preserved the part’s extremely complex geometry while taking into account the needs and requirements of the customers, including optimal cooling requirements as well as the highest release requirements.

Solution

  • Part material (resin): PP / PE
  • Part nominal thickness: 3mm
  • Part weight: 2.6kg
  • Surface finish cavity, core: TEXTURE / SPI-C3
  • Press: 1300T
  • Annual forecast: 600,000
  • Mold type: prototype plastic injection mold
  • Manufacturing location: TIBO CANADA
  • Number of cavities: 1
  • Cycle time: 62 seconds
  • Steel type: P20HH
  • Injection type: Hot Runner 9 drops valve gate reverse with sequential filling
  • Ejection type: hydraulic
  • Mechanism description: 1 retractable slider, 3 hydraulic mobile blocks, 22 lifters, & 8 lifter pads
  • Size of mold (inches): 56’’ X 80’’ X 55’’
  • Mold weight (pds): 47,300

Automotive B-Pillar Upper Cover

Challenge

The aesthetic requirements of the customer were extremely high for the partition line (parting line) with a "0" grain stop on both sides of the part between slides and the surface of the main cavity. An integrated jacket hook on a B-pillar made to eliminate additional components, but requiring a complex mold structure in an already very confined environment, was also manufactured.

Results

We exceeded customer expectations through the completion of an "invisible" partition line on the grain surface with TIBO special proprietary mold design and manufacturing process. The integrated hook was produced successfully on the B-pillar, thanks to the retractable mechanism efficiently designed and produced within other numerous highly complex mechanisms to unmold the challenging internal structure of the part.

Solution

  • Part material (resin): PP talc
  • Part nominal thickness: 3mm
  • Part weight: 353g
  • Surface finish cavity (Core): TEXTURE / SPI-C3
  • Press: 400T
  • Annual forecast: 600,000
  • Mold type: prototype plastic injection mold
  • Manufacture location: TIBO CANADA
  • Number of cavities: 2
  • Cycle time: 38 seconds
  • Steel type: P20HH
  • Injection type: Hot-Sprue
  • Ejection type: hydraulic
  • Mechanism description : 6 retractable & mechanical sliders, 12 mobile blocks, 8 lifters, & 4 lifter pads
  • Size of mold (inches): 24’’ X 30’’ X 61’’
  • Mold weight pds) : 9,020

Off-road Vehicle Seat Base

Challenge

With a limited budget, we had to produce a part that had to be highly resistant to mechanical breakage within narrow dimension’s tolerances. The design of the part had to take into account an unconventional cooling structure and mechanism.

Results

The molds were successfully produced at TIBO Asia through the close collaboration of the design team, the material experts (resin), and the highly technical expertise of TIBO team. The requirements were met by an innovative "entire process solution". We have also designed and produced perfect high performance cooling characteristics and a sequence of complex, but effective, mechanical movements.

Solution

  • Part material (resin): resin with high fiber content (confidential)
  • Part nominal thickness: 0.138"
  • Part weight: 4055g
  • Surface finish cavity (Core & cavity): TEXTURE
  • Press: 1800T
  • Annual forecast: 50,000 units
  • Mold type: production plastic injection mold
  • Manufacturing location: TIBO Asia
  • Number of cavities: 1
  • Cycle time: 130 seconds
  • Steel type: equiv. P20H (32-35 HRC)
  • Injection type: 2 drops VG sequential filling
  • Extraction/Ejection : reverse ejection with 4 hydraulic cylinders
  • Mechanism description: 9 hydraulic slides and 4 lifters
  • Size of mold (inches): 47" X 53 X" 52"
  • Mold weight (pds): 22,100

Automotive Front Grill Assembly

Challenge

We had to deliver—in a very short period of 10 weeks, and with a limited budget--the assembly of 15 injected components for an automotive product with superior quality aesthetic finishing, as well as ensuring the processes of painting and plating.

Results

35 impeccable assemblies were delivered within 10 weeks from the production of components at TIBO Asia to delivery in Mexico. We produced three very complex prototype molds that required a low-cost mold assembly. The quality of the assembly met the customer's requirements, even exceeded the requirements established by the customer production’s assembly.

Solution

  • Part material (resin): ABS & PC-ABS
  • Assembly total weight: need confirmation
  • Surface finish: grained, painted and chromed
  • Mold type: prototype plastic injection mold
  • Manufacturing location: TIBO Asia
  • Mold specifications: confidential