North American Injection Mold Tooling Standards and ......Mold design. 3D solid. Mold build. Mold...

MA-E-305 Revision 5 27-May-2020

North American Injection Mold Tooling

Standards and Requirements.

Release 5 dtd. 5/27/2020

Thank you for being a valued vendor to Minth.

As an Injection Mold supplier it is Minth’s expectation that your company is the expert in

this field. It is also Minth’s expectation that you have the expertise and experience to know

the requirements for the product, part material, mold material, mold type and function of

the mold required to make the mold that has been contracted.

The contents of this document are to be the overall guidelines and procedures to construct

injection molds for Minth North America. The vendor’s program manager is responsible

for notifying the Minth Tooling Engineer of any items requiring authorizations that are

spelled out in this document. He/she is also responsible for procuring any authorizations

required for any items listed as requiring authorization in this document.


Contents

I. Quoting page 5

II. Procedures & Timing page 8

Mold Construction Only page 11

III. Mold Validation page 12

IV. Design page 16

V. General Mold Construction page 23

VI. Cooling & Water Lines page 31

VII. Slides page 34

VIII. Lifters page 35

IX. Ejection page 36

X. Gates & Runners page 39

XI. Hot Runner Manifolds page 40

Valve gated Hot Runner Manifolds page 42

XII. Venting page 43

XIII. Locating Ring page 43

XIV. Texturing page 44

XV. Hydraulics page 44

XVI. Prototype page 46

XVII. Mold Requirements for Chrome parts page 46

Product Design page 46

Gating page 47

Venting page 47

Processing page 47

General Construction page 47

XVIII. Dual Shot Injection Molds page 48-52

Rotary Platen Injections Molds

Press Spécifications

XIX. Moldflow page 52-55

XX. Vendor Contractuel Agreement page 56-58

Appendices :

IM Vendor kickoff form MA-EP-410

Minth NA Supplier I M

kickoff form MA-EP-410.xls Click on File

IM Block-out check list MA-EP-405


Minth NA I M

Block-Out MA-EP-405.xls Click on File

IM Authorization to order steel_______________________________ MA-EP-409

Minth NA I M

Authorization to order form MA-EP-409.xls Click on File

IM Preliminary Design check list MA-EP-406

Minth-NA I M

Preliminary design chk list MA-EP-406.xls Click on File

IM Final design check list MA-EP-407

Minth NA I M FINAL

design chk list Form MA-EP-407.xls Click on File

IM Validation Buy-Off form MA-EP-408

Minth-NA I M Tooling

Validation and Buy Off Forms MA-EP-408.xls Click on File

Schematics: Figure 4.4a&b Engineering change & Title Block

Figure 4.4c-1 Core Plan View

Figure 4.4c-2 Cavity Plan View

Figure 4.4c-3 Horizontal Section

Figure 4.4c-4 Vertical Section

Figure 4.4c-5 Side View Operator Side


Figure 4.4c-6 Side View Non-Operator Side

Figure 4.4c-7 End View

Figure 4.4c-8 Maximum Daylight

Figure 4.4c-9 Exploded View

Figure 4.4c-12 Manifold

Figure 4.4c-12a Manifold Wiring

Figure 5.34 Pillar Standoffs

Figure 5.44 Mold Identification

Figure 5.54 Guide Pins

Figure 5.66 Rails and Support Pillars

Figure 5.73 Insert wedges

Figure 6.16 Water Main In & Out

Figure 7.14 Horn Pins & Slides

Figure 9.22 Threaded Knock out

Figure 9.26 Swing Arm Limit Switches

Figure 9.30 Hydraulic Ejection

Figure 13.6 Reversible locating ring

Figure 17.6 Flow Length Chart

Figure 18.4 300 Ton Vertical Clamp plate notch

Figure 20.10 300 Ton vertical Dual Manifold

Figure 21.5 450 Ton Locator Block

Figure Press Specs

Figure

I Quoting:

1.1 All programs that have injection molds as part of the quotation and have the molds

shipped to North America, will be based on this Minth North American Injection Mold

Tooling Standards.

1.2 All North American programs that have injection molds quoted as part of the quotation

and have the molds manufactured overseas, will be based on this Minth North American

Injection Mold Tooling Standards.

1.3 All quotes are to have the statement: “Quoted to the terms and conditions of the Minth

North American Injection Mold Tooling Standards. Release Dtd 5/12/2020.

1.4 When quoting new programs that include injection mold tooling a full list of assumptions

for the given mold are to be provided.

1.5 When quoting new programs a sketch showing mold layout, part orientation, gating

assumptions are to accompany the assumptions sheet.

1.6 Each quote is to include the following information as a separate line item for:


Mold Cost consisting of and itemized with the following.

All requirements in these MNA Injection mold tooling standards.

Mold design. 3D solid.

Mold build.

Mold construction.

Steel type for the Core block, Core insert block, Cavity insert block, Cavity insert block.

Location and source that steel will be purchased from.

Material.

Texturing.

Hot runner manifold if applicable.

Cost for the hot runner manifolds are to be itemized.

Timing:

To first molding trial. T0, T1, T2

Ready to ship un-textured.

Ready to ship textured.

Mold validation in the North America if shipped to North America.

Delivery to the designated Minth plant in North America.

Cost and timing for shipping from Overseas to the vendor’s North American

facility.

By boat.

By airfreight.

Cost to texture the mold in Overseas.

Specify type of grain that is quoted.

Who the grain source is.

Mold filling analysis. Itemized as separate cost.

Filling analysis is to include the manifold from the machine nozzle inlet.

Mold integrated warp analysis. Itemized as separate cost.

Warp analysis must be provided in Mold flow version 4 if Mold flow version 6

is used.

Warp analysis in to include cooling lines.

Note: If the mold is a two shot mold it will require mold filling and warp analysis on both

molds.

For all GM jobs mold filling analysis must be done by one of the following

GM approved sources:

FEAMold

Pro Mold

CAE

Manufacturer and type of steel:

Inserts for the cavity, core and slides.

All molds quoted to be shipped to North America are to be quoted with

steel per the matrix provided:

300 pc. Mold function capability run in Overseas.


Ref. Section III Mold qualifications.

Manifold and drops.

All molds with hot runner manifolds are to be manufactured using one of the

following manifold suppliers: Incoe or Synventive.

1.7 Molds are to be quoted F.O.B. the Minth’s designated plant if shipped to North America.

Itemize delivery to the following locations:

Tawas, MI.

Aguascalientes Mexico

Tennessee.

1.8 Mold designs for all North America programs must be approved by the designated North

American Tooling Engineer of the Farmington Hills office prior to construction.

1.9 When quoting engineering changes factor in cost for all Texturing, venting, ejection,

cooling, gating, print updates, data updates, molding trials and support required to make the

change being requested.

Note: All engineering changes are to be validated with a molding trial.

1.10 For all new programs that have the tooling being built and developed overseas, the

following costs are to be covered within the cost of the injection mold cost.

Air freight of up to 15 first shot parts. 30 if a handed part. Including packaging.

Air freight of up to 150 parts or sets if handed for each of the first 3 preproduction builds

required by the OEM. Including packaging.

1.11 Upon the receipt of the mold in North America, the mold will be disassembled for cleaning

and inspected to verify that the mold was built to the Minth North American Injection Mold

Tooling Standards, for craftsmanship and the approved design. If required all open issues

that require addressing will be identified, itemized and quoted.

1.12 Any cost associated with mold not meeting the Minth North American Injection Mold

Tooling Standards, approved design or fixing craftsmanship issues will be charged back to

Vendor.

1.13 Buy-off of all molds are based on fulfilling the mold validation requirements outlined in

section III and the vendor contractual agreement in section III Mold Validation.

1.14 A five-piece CMM layout of parts from each tryout is required.

1.15 When quoting future work, the model year must be taken into account. Quoted mold

costs are to have model year economics and be good for that time frame of release. If no

time frame is stated when the quote is given then a 6 month time frame to release is to be

used.


1.16 In the case of production pull ahead and prototype, it should be understood that there

may be quantities required for pilot builds, process setup, etc. Vendors should plan on

running as many as 300 shots at any and all regularly scheduled tryouts.

1.17 Production molds are to be manufactured from the designated steel outlined in these

standards.

1.18 All molds built for a glass filled material with a GF content of 25% and less are to be quoted

with the part surface nitride treated to a depth of .0002” depth.

1.19 All molds built for a glass filled material with a GF content of 30% or greater are to be quoted

with H-13 steel insert constructions.

1.20 For molds that are manufactured with core and cavity inserted blocks into a mold base, the

inserted steel is to be large enough to allow all gating, runners and drops to hit the inserted

steel.

1.21 Prototype molds are to be quoted as manufactured from “1040 P-20 Soft Steel” or

equivalent, NOT aluminum, unless otherwise authorized. Ref. Section XVI Prototype

1.22 Mold cost must include mold filling, cooling and integrated warp analysis. The cost for each is

to be individually itemized on all mold quotes. Mold flow analysis must meet the

requirements of the OEMS.

1.23 Reference section XVI when quoting Prototype molds, XVII for dual shot molds and XVII for

vertical press mold requirements.

1.24 In the case of a two shot “pick and place” molds, the quote is to factor in the cost for

dimensional layout of at least 5 parts to qualify the substrate prior to tuning it into the

second shot mold.

1.25 For any injection molds manufactured overseas that are to be shipped to North America

requires a list made of the items that do not meet the given design or these standards. The

Vendor will have the opportunity to fix and update these items prior to shipment if time

permits. Upon receipt of the molds in the US any items found not to be corrected or not

meeting the design or standards will be quoted with cost and timing to be updated.

1.26 All molds are to include RJG pressure sensors 3 Per Cavity and assume ejector pin

pressure sensors and mold mounted plug.

1.27 All molds, gages and secondary equipment are to be quoted per the contractual agreement

of Minth North America purchasing stated in section XXIX.


II. Procedures:

The following outlines the procedures that are to be conducted for all injection mold tooling

built for Minth North American programs.

2.1 It is the vendors responsibility to be able to read and manage the following types of data:

Unigraphics UG

Catia

IGES translations.

STEP translations.

2.2 Outsourcing of manufacturing for any components associated with building molds for Minth

North America is to have written approval.

2.3 All Tier II suppliers are to be approved by Minth North America.

2.4 All direction for mold design, approvals, authorizations and changes are to be communicated

through the Minth North American Tooling Engineer at the Wixom MI office.

2.5 It is the responsibility of the Vendor to have all check list outlined in these standards

filled out with necessary approvals attached when submitting an invoice for payment.

2.6 Mold designs are to be submitted in a 2D and 3D math file formats as outlined in the section

IV of these standards.

2.7 If the tooling source has been contacted to do Mold flow and integrated Warp analysis, it is

to be started approximately 2 weeks prior to mold kickoff with preliminary data to determine

gating locations, drop locations and to identify any product design flaws. Once the

preliminary mold design is complete and final released data has been issued the mold flow

and warp analysis is to be redone to verify initial results.

2.8 At the time of mold kickoff, the Minth Tooling Engineer will issue the Supplier Injection

Mold kickoff sheet (E-MA-410) to the designated tooling source. This sheet will have all the

pertinent information to proceed including completion dates. The designated source will

sign and email back the kickoff sheet to the Minth Tooling Engineer as an acknowledgement

that he or she is in agreement with the dates and information.

2.9 In addition to the kickoff sheet the supplier is to fill out the Minth mold build Timeline and

return it with the signed kickoff sheet.

2.10 Minth’s designated tooling shop is to complete a Block-out, Preliminary and Final Design

with the Check lists for each level of design filled out to ensure that all requirements have

been met. These check lists are to be accompanying the designs when submitted for review.


These check lists will ensure that issues requiring authorization have been signed off by both

the Minth Plant Engineer and Tooling Engineer.

2.11 A Block-Out design and authorization to order steel form is to be submitted along with

the Block-Out design check list (E-MA-E-405) properly filled out within one 10 working days

of mold kickoff. The block-out design must include all pertinent information required to

discern proper block size, mold function and packaging of mold components within the

environment. The block out design is to include the mold material designation form as well

as an individual schematic of the insert block. This schematic is to include the following: Four

view schematic; FV, PV, SV & prospective View of the block or blocks, Finish block size,

Material (type of steel)

2.12 When the Blockout design is submitted it is to be accompanied by Minth’s detailed time line

showing all phases of the build from kickoff to shipping the mold to North America.

Reference: Form (MA-EP-412)

2.13 The signed Block-Out design check list (MA-EP-405), along with the Minth Injection Mold

Authorization to order steel form (MA-EP-409) will be the authorization for the vendor to

purchase the Core, Core Insert, Cavity, Cavity insert and slide steels ONLY. This Block-out

is to be reviewed and signed by the Minth Tooling Engineer within two days of receipt.

2.14 During the design process 2D prints and 3D math files are to be put on an ftp site for

review at a minimum of Monday of each week until the Preliminary design is complete. The

Preliminary Design Check List (MA-EP-406) can be properly filled out showing compliance

with these standards for approval within 3 weeks of mold kickoff. This preliminary design

check list is to be reviewed and signed by the Minth Tooling Engineer within three days of

receipt.

2.15 A schematic of the core showing the location of all the nomenclature required is to be

presented with the preliminary design. All nomenclature is to be etched or engraved (not

stamped). This schematic is to be signed by the Minth Tooling Engineer and Program

Manager and return to the Minth program manager as authorization for engraving.

2.16 NO steel is authorized to be cut prior to receipt of preliminary design check list signed by

the Minth North American Tooling Engineer.

2.17 A Final mold design is to be submitted along with the Final Design Check List (MA-EP-

407) properly filled out showing compliance with these standards for final approval. The final

designs are to have separate 8 ½” X 11” schematics attached to the check list for: Water

system, manifold and zones, manifold wiring and hydraulic system. The final designs are to

be completed by the end of the 6th week from kickoff.

2.18 All molds are to have an Intermediate 70%, and Final 90%, build stage and individual

component craftsmanship review. These reviews are to be done with the Minth tooling

engineer present whenever possible. If a Minth Tooling engineer cannot be present for this

review a video presentation is to be put together and emailed to the Minth Tooling engineer.


This video must have detail to demonstrate build craftsmanship of all components. Items

such as venting, benching level etc. must be able to be seen.

2.19 Intermediate 70% review: This review will take place at approximately the 70% phase of

the build. This review is to be shown on the mold build time line. This review is to be a

complete component level review as outlined in the Final 70% component review check

sheet. The vendor is to have all individual components available to be inspected.

Reference: Form (EP-MA-413)

2.20 Final 90% review: This review will take place before final assembly. This review is to be

shown on the mold build time line. This review is to be a complete component level review as

outlined in the Final 90% component review check sheet. The vendor is to have all individual

components available to be inspected. The 90% review is to take place no later than 2.5weeks

prior to T1 molding trial.


2.21 The tooling source will perform a molding trial T1 on or before the completion date agreed

to on the injection mold kick-off form and mold build timeline. A T1 molding trial constitutes

a mold that is complete, fully benched to the specified surface quality and flash free. At that

time parts will be marked up and an action sheet will be filled out to itemize the issues that

need to be addressed.

2.22 The tooling source is to produce 5 shots with runners and ship to the required plant for the

production of EOA and Degator.

2.23 Minth’s designated tooling source is to have a second T2 molding trial within ten days of

the first molding trial date. All the issues are to be corrected from the write up done at first

shot trial. If a third or more trial is required to deliver a satisfactory part and or mold, will be

carried out by the vendor with all due diligence to maintain the timing stated herein.

2.24 Minth’s designated tooling source is to have a third molding trial within 3 weeks of first shots

with the mold fully production capable and ready to ship to the Minth facility. Ref. Mold

qualifications.

2.25 If the mold is textured, Minth’s designated tooling source will have a molding trial with the

mold textured within two and one half weeks of having pre-texture approval.

2.26 Minth’s designated tooling shop is responsible to manage the grain source vendor. It is the

responsibility of the grain source vendor to do any fixes or repairs to the grain until AAR

approval for PPAP is achieved.

2.27 Minth is expected to complete the 300 pc. Mold function capability run within 3 weeks of the

first molding trial, within 6 weeks of the first molding trial if the mold is grained.

2.28 MINTH will not be responsible for any costs of any tooling or changes done without a

purchase order and Authorization from the Minth Program Manager.


2.29 Minth’s designated tooling shop is responsible for providing to the Minth program manager

open issues and bi-weekly mold build progress reports for the Minth Tooling Engineer.

2.30 The biweekly mold progress reports will track the mold build progress per the timeline

provided by the Minth designated tooling shop. Photos of the mold build progress need to

accompany the progress report.

2.31 Minth will conduct a 300 pc mold function capability run to qualify the mold. The Vendor

Injection Mold Acceptance form is required to be filled out with all issues stated and

signed by the Minth tooling engineer and a MINTH representative prior to mold shipment.

Mold Construction Only:

When Mold design is provided by Minth North America

2.32 The mold is to be manufactured to the design provided and in accordance to these

standards.

2.33 When the mold design is provided by Minth, a purchase order will be issued for the mold

construction cost only.

2.34 At the time of mold kickoff a complete mold design in a solid .prt file with a B.O.M., bill of

material list that provides all pertinent information to start the manufacturing of the mold.

2.35 Within one week of the Tooling Source receiving a tooling purchase order the Tooling source

is to issue a purchase order to the hot runner manifold supplier and provide a contact name

to the Minth tooling engineer.

2.36 Within one week of the mold kickoff the Tooling Source will order the steel per the B.O.M.

(bill of material). The four main steel blocks are to be ordered at that time. Once the mold is

complete it is to be qualified in the manor outlined in section III mold qualifications.

III. Mold Validation:

3.1 All molds built for Minth North American programs are to be validated by the mold build

validation process outlined in this section.

3.2 The mold build and validation process includes the following steps: It is the vendor’s

responsibility to fill out all pertinent forms and provide them to the Minth North American

Tooling Engineer for approval.

Note: all of the forms are to be submitted to Minth when invoicing for payment.

Intermediate (70%) component level review.

Final component (90%) level review. Note: the 90% component level review is to be done at least 2.5 weeks prior to T1.

T0, T1, T2 level molding trials.

Textured level molding trial if required.


o “Vendor” 300 shot mold function validation molding trial.

All mold acceptance forms are to be filled out.

o “IN-Plant” 300 shot mold function validation molding trial.

All mold acceptance forms are to be filled out.

3.3 All molds built in North America are to have a production “buy-off” molding trial with a

Minth Tooling engineer representative present. The injection mold acceptance form is to

be filled out with the MINTH representative authorizing shipment.

3.4 All molds built overseas for delivery to North America are to have a production “buy-off”

molding trial in Overseas with a Minth Farmington Hills representative and a Minth plant

representative present. The injection mold acceptance form is to be filled out with the

Minth representative authorizing shipment.

3.5 All molds are to have an Intermediate 70%, and Final 90%, build stage and individual

component craftsmanship review. These reviews are to be done with the Minth tooling

engineer present whenever possible. If a Minth Tooling engineer cannot be present for this

review a video presentation is to be put together and emailed to the Minth Tooling

engineer. This video must have detail to demonstrate build craftsmanship of all

components. Items such as venting, benching level etc. must be able to be seen.

3.6 Intermediate70% review: This review will take place at approximately the 70% phase of

the build. This review is to be shown on the mold build time line. This review is to be a

complete component level review as outlined in the Final 70% component review check

sheet. The vendor is to have all individual components available to be inspected.


3.7 Final 90% review: This review will take place before final assembly. This review is to be

shown on the mold build time line. This review is to be a complete component level review

as outlined in the Final 90% component review check sheet. The vendor is to have all

individual components available to be inspected. The 90% review is to take place no later

than 2.5weeks prior to T1 molding trial.


3.8 The vendor will perform a T0 molding trial prior to the mold due date to identify any major

issues that may prevent success at the T1 “First shot” molding trial. The T0 molding trial is to

be a non-published trial on the timeline.

3.9 The vendor will perform a T1 molding trial prior to the mold due date to identify any major

issues that may prevent success at the T1 “First shot” molding trial. The T1 molding trial is to

be on or before the published timeline. The vendor is responsible for putting together an

open issues list of any open issues that require fixing.

3.10 The vendor will perform a T2 molding trial 10 days after the T1 molding trial with any

issues identified from the T1molding trial fixed. All open issues from the T1 trial will be

reviewed and evaluated to verify that they have been addressed.


3.11 If there are any issues remaining the vendor and the Minth tooling engineer will determine

if a T3 molding trial is required.

3.12 If the mold is textured; a minimum of 3 sets of parts are to be submitted for “Pregrain”

approval and grain mapping.

3.13 If the mold is for a chromed part; the vendor is to supply parts for Minth to perform a

chrome process upper and lower limit DOE on the parts from the T2 or T3 molding trials. 6

parts from each setup are to be provided to the chroming department to validate the

process for chrome adhesion.

3.14 Upper and lower limit Chrome DOE molding trial; three process setups are to be run as

outlined in the Upper and Lower limit Chrome DOE process setup sheet.

3.15 Once “Pregrain” approval has been given the vendor is to send the mold out to the texture

source.

3.16 Once the mold has been textured the vendor is responsible to perform a grained molding

trial. 3 sets of parts are to be submitted from this trial for “post” texture approval.

3.17 Once the mold is considered complete the vendor is to perform a “Vendor Run” mold

function molding trial. The mold acceptance check list is to be filled out along with the

“Vendor Run” part evaluation sheet identifying any issues that exist. This trial requires

signoff by the Minth NA Tooling engineer and a representative of the Minth manufacturing

plant. This document is to be accompanied by a copy of the molding process setup sheet.

3.18 Once the mold has been shipped to the Minth manufacturing plant, the plant is required to

setup a molding process from the process sheet that came from the Vendor run trial. The

plant is to work with the vendor to run an “In-plant” validation molding trial. The In-plant

part evaluation sheet is to be filled out at that trial. If the mold is functioning properly and

making a good part then the sheet is to be marked as mold accepted. If there are issues

that are mold related the vendor is responsible for fixing those issues.

3.19 Injection Mold Validation signoff documents:

Form: MA-EP-408

3.19A Check list: pages 1 & 2

3.19B Vendor Trial part evaluation sheet: page 3

Include process sheets from trial.

3.19C In-Plant Trial part evaluation sheet: page 4


3.19D E/C Trial part evaluation sheet: page 5



3.19E History log: The history log is a log of each molding trial detailing the events of the

molding trial, parameters, issues and plan of action for next trial. page 6, 6A…

3.20 Molds built for Chrome parts: Are to have an “upper and lower” limit molding trial DOE.

This molding trial will be based on the “upper and lower” limits trial format.

3.21 A 300 shot mold function molding trial is required on all injection molds. After a process

has been established, every 10th part from this run is to be boxed separately and shipped to

Minth Wixom office. Parts must be numbered with shot sequence.

3.22 For the 300 shot mold function molding trial the vendor is to supply pigtails that match the

plugs on the mold for the tryout facility to wire to. The plugs are not to be dismantled for

the tryout and rewired for shipment.

3.23 For the 300 shot mold function molding trial, the mold is to be fully assembled with all

water manifolds, electrical, hydraulics, etc. Ready to ship condition.

3.24 For molds built overseas and shipped to North America the Vendor is responsible to deliver

the mold cleaned up and ready for trial.

3.25 It is the Tooling sources responsibility to produce a mold to these Standards. The mold

must produce a part that are dimensionally correct, flash free and meets the appearance

criteria of the OEM. These parts must be to the specified wall thickness, before and after

being textured.

3.26 It is the responsibility of the Tooling source to build a mold that will achieve a signed AAR

(Appearance approval Report) from the OEM or Tier One supplier to qualify a mold as

complete. It is the Tooling sources responsibility to make the necessary adjustments to

achieve a process that will produce a part capable of matching a gloss plaque and a signed

AAR.

3.27 It is the Tooling sources responsibility to manage the texturing source until a signed AAR

approval is achieved.

3.28 All molds must be certified to GD&T in car position with all check points agreed to by the

Minth Program Manager, Tooling Engineer and Minth prior to final design.

3.29 CMM certification of both Core and Cavity (steel checks) is required for all molds. Overall

length, width, attachment points and OEM significant characteristic points must be included

in layout. Layout and all schematics (water, electric, hydraulic) and final mold designs must

accompany mold for shipment.

3.30 Any preliminary tryouts by the tooling vendor for the establishment of wall thickness, shut-

offs, parting line match etc., shall not constitute fulfillment of the above tryout


requirements. The cost of all additional tryouts to fulfill the above requirements will be the

financial responsibility of the tooling vendor.

3.31 If, after the mold is grained, it cannot meet the same requirements as outlined the tooling

vendor is responsible to correct the mold at his own expense and to incur all cost

associated in accomplishing the corrections

3.32 In the case of a two shot mold, the vendor is responsible for qualifying the substrate

through a dimensional layout of at least 15 parts prior to tuning it into the second shot

mold.

3.33 Warranty: The Tooling source is required to warrant the mold for the period of 5 years and

“mold life expectancy” of 1,000,000 cycles after the mold validation has been completed at

the Minth facility. This warranty includes any tier two suppliers that the vendor may have

used.

3.34 Therefore, the mold design, materials and components used in the construction of any

molds built for Minth are to ensure that the “mold life expectancy” of the mold can achieve

the 1,000,000 cycles.

3.35 The vendor is to supply a recommended maintenance manual and schedule for each mold

that outlines the preventative maintenance required.

IV. Design: 4.1 All designs and surface files are the property of Minth.

4.2 Block-out mold designs must include the following information.

4.2a. Plan view and side view of clamp plates, core and cavity block sizes.

4.2b. Vertical and horizontal sections that show all slides and lifters in both there mold closed

position and mold open position.

4.3 Preliminary mold designs must include the following information.

4.3a. Title Block: Bottom right corner of print.

Part Name.

Part Number.

Material to be molded.

Shrink factor.

Mold weight

Core

Cavity

Total

Machine to be used.


Print Data release level date.

Print engineering change level.

Print sheet name: i.e. Core Plan View

Ref. Fig. 4.3a & b

4.3b. Engineering Change Block: Upper right corner of print.

Engineering change level and change description.

Ref. Fig. 4.3a & b

Prints, views, sections:

4.3c. Colored pdf files of the following are to be provided of the following:

1. Core plan view:

With core material called out above title block.

Machine to be used, including tie bar positions.

Core benching finishes.

Fully dimensioned.

2. Cavity plan view:

With cavity material called out above title block.


Cavity benching finishes.

Fully dimensioned.

3. Horizontal Section through C/L, fully d

Fully dimensioned.

4. Vertical Section through C/L and any pertinent details. Sections must include or have

breakaway detail of: Leader pin, guided ejection pin and return pin.

Fully dimensioned.

5. Side view (operator side) of core and cavity together with dimensions.

Fully dimensioned.

6. Side view (non-operator side) of core and cavity together with dimensions.

Fully dimensioned.

7. End view of core and cavity together with dimensions.

Mold stack up dimensions to be shown:

A. Cavity Block thickness.

B. Core Block thickness.

C. Overall shut height.

D. Main parting line to front of ejector plate.

E. Diagonal.

F. Extended Clamp plate length & width.

G. Daylight between lifters and cavity at full ejection stroke.

H. Daylight between core and cavity in mold open position.


J. Manifold spacer plate.

8. Maximum daylight View showing the daylight between core and cavity in the

maximum press opening position.

View showing the daylight between lifters, slides etc. and cavity at maximum ejection

stroke.

9. Runner and gate details.

All gates and runners are to be detailed and dimensioned.

10. Block out of Hot Runner Manifold.

11. Texture:

Name and number

Gloss

Source.

4.4e. All views are to show location of:

Electrical box.

Water manifolds.

Hydraulic manifolds or fittings.

Plaques.

Final mold designs must include the following information:

4.4a. Title Block:

Part Name.

Part Number.

Material to be molded.

Shrink factor.

Mold weight.

Machine to be used.

Schematic 4.4 a&b Eng. change and Title block.pdf Click on pdf.

4.4b. Engineering Change Block:

Engineering change level and change description.

Ref. Fig. 4.4a

4.4c. Prints, views, sections:

1. Core plan view:

With core material called out above title block.

X,Y,Z location of tooling balls, dowel pins and locating holes must be shown.

Size and stroke of cylinders.



Core benching finishes.

Ref. Fig. 4.4c-1 Schematic FIG 4.4c-1 Core Plan View.pdf Click on pdf.

2. Cavity plan view:

With cavity material called out above title block.

X,Y,Z location of tooling balls, dowel pins and locating holes must be shown.

Cavity benching finishes.

Ref. Fig. 4.4c-2 Schematic FIG 4.4c-2 Cavity Plan View.pdf Click on pdf.

3. Horizontal Section: Through C/L, fully dimensioned and detailed with any pertinent

details.

Ref. Fig. 4.4c-3 Schematic FIG 4.4c-3 Horizontal section.pdf Click on pdf.

4. Vertical Section through C/L, fully dimensioned and detailed with any pertinent details.

Ref. Fig. 4.4c-4 Schematic FIG 4.4c-4 Vertical section.pdf Click on pdf.

Sections must include or have breakaway detail of: Leader pin, guided ejection pin and return pin.

5. Side view (operator side) of core and cavity together, fully dimensioned and detailed with

any pertinent details.

Ref. Fig. 4.4c-5 Schematic FIG 4.4c-5 Side View Non-Operator side.pdf Click on pdf.

6. Side view (non-operator side) of core and cavity together, fully dimensioned and detailed

with any pertinent details.

Ref. Fig. 4.4c-6 Schematic FIG 4.4c-6 Side View Non-Operator side.pdf Click on pdf.

7. End view of core and cavity together.

Mold stack up dimensions to be shown:

a. Cavity Block thickness.

b. Core Block thickness.

c. Overall shut height.

d. Main parting line to front of ejector plate.

e. Diagonal.

f. Extended Clamp plate length & width.

g. Daylight between lifters and cavity at full ejection stroke.

h. Daylight between core and cavity in mold open position.

i. Manifold spacer plate.

Ref. Fig. 4.4c-7 Schematic FIG 4.4c-7 Dimensioned End View.pdf Click on pdf.

8. Maximum daylight View showing the daylight between core and cavity in the

maximum press opening position.

View showing the daylight between lifters, slides etc. and cavity at maximum ejection

stroke.

Ref. Fig. 4.4c-8


9. Exploded views.

There are to be enough exploded views to show all components and each

component is to have a ballooned number that corresponds to the number on

the BOM.

Ref. Fig. 4.4c-9 Schematic FIG 4.4c-9 Exploded view Cavity.pdf Click on pdf.

10. Schematics of:

Overall mold dimensions and tie bar spacing.

8 ½” X 11” Manifold and zones schematic.

8 ½” X 11” Manifold wiring schematic.

8 ½” X 11” cooling system schematic, Cavity.

8 ½” X 11” cooling system schematic, Core.

8 ½” X 11” Hydraulic system schematic.

Mold open sequence.

11. Runner and gate details.

All gates and runners are to be detailed and dimensioned.

12. Manifold print must include:

Manifold assembly layout.

Complete detailed components list.

Schematic of the hot runner construction.

Location of the heater.

Location of thermocouple zones.

Heater wattage and resistance.

Pin wiring schematic.

Ref. Fig. 4.4c-12 Schematic FIG 4.4c-12 manifold.pdf

Schematic FIG 4.4c-12a manifold wiring.pdfClick on pdf.

13. Texture:

Name and number

Gloss

Source.

4.4d. All views are to show location of:

Electrical box.

Water manifolds.

Hydraulic manifolds or fittings.

4.4 All components must be identified with a balloon corresponding to the stock list and or detail

print number.

4.5 The tie bars for the designated press are to be shown in design.


4.6 All press information is to be stated in the end view of one of the tie bar ends.

4.7 Sections must include or have detail of: Leader pin, guided ejection pin and return pin.

4.8 Block out, preliminary & final designs are to be placed on an ftp site for electronic transfer to the

MINTH Inc. Tooling Engineer as outlined in these standards.

4.9 Any parting lines on class “A” surfaces must be shown in the design with a dashed line and

submitted for approved to the OEM Engineer via the MINTH Inc. Tooling Engineer.

Written authorization is required.

4.10 Crossover parting lines should be avoided unless approved by Minth Plant Engineer.

Written authorization is required.

4.11 Final designs are to be submitted both in a print format and 3D math data to the Minth. Tooling

Engineer. Both the print and 3D data are to be put on an ftp site in IGES format and native

code (format in which mold was designed) and all surface files for the mold.

4.12 All molds are to be designed with the required OEM Symbol and Verbage.

4.13 All nonstandard components subject to wear and breakage or purchase components that have

been altered must be detailed.

4.14 All molds to be designed with DME or equivalent standard components.

4.15 All standard components must have the following information in the Bill of Material:

Vendor; address and phone number.

Catalogue Number.

4.16 All mold modifications / engineering changes must be reflected in designs. The vendor must

incorporate a change block into drawings to clearly describe the nature of change as well as the

date.

4.17 Runners and gates are to be detailed and dimensioned.

4.18 All molds requiring 250 Tons and up are to be built with hardened (Rc 48-52) steel net pads.

These net pads are to be placed around the perimeter of the mold. The maximum distance

between net pads shall be no greater than 14” / 355mm.

4.19 The total of the net pads, corner locks, shutoff around the perimeter of the part and the internal

shutoffs are to be designed to be between XXX and XXX Tons per square inch.

Ref. Fig. Parting line tonnage calculation

4.20 If the mold is built with net pads then no pry slot is required.

4.21 Ejector pin locations must be approved by the Minth Tooling Engineer. Written authorization is

required. All ejector pin locations must be numbered on the print. The corresponding number


is to be engraved into the head of the ejector pin. Ejector pin identification.jpg click on ref.

photo

4.22 All threaded items susceptible to loosening must be secured in place using NYLOK screws or

jam locking devices and must be shown in detail in designs. Lifter rods MUST use NYLOK

screws for fastening.

4.23 Travel of moving parts shall be dimensioned and shown with phantom lines in the mold open

position at full ejector stroke.

4.24 Off-set corner of core, cavity, plates and rails shall be identified with a “0” stamped in a location

visible during assembly of the mold.

4.25 The zero corner Guide pin must be off-set in one direction so the mold cannot be assembled

incorrectly. Use .25”; 6.35mm for molds of 300 Tons and smaller and .625” 15.875mm for molds

350 Tons and larger

4.26 Flow direction of all water circuits must be shown with dashed lines and arrows throughout the

water line

4.27 Show 25.0 mm wide parting line shutoff zone with dashed lines in views, clearance past shutoff

is to be shown in sections.

4.28 Avoid hydraulic or pneumatic actuated slides and pins.

4.29 Lifters, slides, ejector pins and core pins are to be numbered in the design.

4.30 All components; lifter rods, gibbs, slides, guides that correspond to that lifter head or slide must

have labeled with the corresponding number and a letter suffix. i.e. The rod with lifter 1 would

be labeled 1A.

4.31 All molds are to be equipped with a flush mounted Progressive Components Cycle counter, and

should be mounted on the operator side of mold. Progressive cycle counter.JPG click on ref. photo

4.32 Provide note showing that there is a stop button under the return pins.

4.33 Provide note in sections showing the angle of the parting line lock and any interior shutoff

angles.

4.34 Vents are to be shown in both, cavity plan, core plan views and sections. Use solid lines in the

side the vents are milled into. Use dashed lines in the opposite side to show location.

4.35 Vents are to be surfaced in math data.


4.36 Reversible runner shutoffs are required for each cavity.

4.37 Reversible Locating rings are required on every tool.

4.38 Any tool designed to run on a magnetic platen must also have bolt holes for clamping as a

backup.

V. General Mold Construction:

5.1 Any errors / discrepancies in drawings, designs or construction are to be reported to

MINTH Inc. / Minth Tooling Engineer immediately and in writing.

5.2 All production molds manufactured for North America programs are to use steel types as

outlined in the chart below for mold construction:

A - Clamp plate steel: LKM 1050

B - Cavity mold base steel: P-20 @ 28-32 Rc through hardness.

LKM 638: P-20

C - Cavity Insert steel: High Hard P-20 @ 30-34 Rc. through hardness.

LKM 718H: HHP-20 For all General Motors molds: Finkl Hi-Hard P20 (P20HH)

D - Core mold base steel: P-20 @ 28-32 Rc through hardness. LKM638: P-20

E - Core Insert steel: P-20 @ 28-32 Rc through hardness.

LKM 638: P-20 F - Slide steel: P-20 @ 28-32 Rc through hardness.

If slide is textured: LKM 718H: HHP-20

For all General Motors molds:

Finkl Hi-Hard P20 (P20HH)

G – Lifter steel: KM 638: P-20

H – Rail steel:

LKM 1050 J – Ejector plate steel:

LKM 1050


5.3 The Chart below outlines the steel type and steel manufacturer for steel that is authorized

to be used in North American injection molds.

5.4 Hardness is to be recertified following stress relief.

5.5 For molds built overseas where the mold base is purchased; it is the responsibility of the vendor to CMM and certify the dimensional accuracy as well that components meet these standards.

5.6 Steel type is to be shown above the title block of the core and cavity plan views.


5.7 For North American Tooling steel is to be purchased based on the steel matrix guide in

section 5.3.

5.8 For all molds using PVC material are too manufactured from Finkle 420 stainless steel.

If manufactured in Overseas use Assab S136 / 136H SS. Ref. Sec. 5.3

5.9 Material certification is required on all steels used. Attach certification to final design check

sheet. Hardness is to be provided in the steel certification in Rc units. Hardness is to be

check in a minimum of 3 places.

5.10 For molds that are manufactured with core and cavity inserted blocks into a mold base, the

insert steel is to be large enough to allow all gating, runners and hot runner drops to be

within the inserted steel block.

5.11 If the mold base is purchased, the mold steel is to be a minimum of 24Rc to 28Rc. Reference

schematic letters B & D.

5.12 Rail, clamp plate and ejector plate steel is to be per the chart above.

5.13 Mold blocks must be stress relieved in a furnace in accordance with the steel supplier’s

recommendations & instruction.

5.14 Cores surfaces where plastic touches the mold surface are allowed to have cutter marks un-

benched unless finer finishes are required to provide adequate part removal and to not

detract from the appearance or function of the product.

5.15 Finish cut indexing step over for all net surfaces must not exceed .25mm / .010 inches.

Finish cut for all non-net surfaces may be .5mm / .020 inch step over. cutter path indexing.jpg Click on Ref. photo

5.16 All benching finishes are to be to the SPI chart below and as stated below.

5.17 Core surfaces that require benching are to be benched to a 320 paper / SPI B-3 finish or

finer.

5.18 Cavities are to be benched to a minimum of a 400 paper / SPI B2 finish or finer.

5.19 Cavities for Chromed parts are to be to a 1200 paper / SPI A-3 #15 diamond polish.


5.20 Blind rib finish shall have a 600 paper / SPI B-1 finish draw finish.

5.21 Parting line surfaces around the perimeter and internal too the part, can have hand ground

spotted finish.

5.22 Parting line surfaces are to be a minimum of 25 mm wide and the remaining surfaces of

the core and cavity are to be cleared 1.0 mm to edge of mold. 25mm parting line.jpg click on ref. photo

5.23 Net pads are to be mounted to the core and cavity to ensure stability and longevity during

clamping. The net pads are to be Rc 48-52 steel. To calculate the number of net pads use

the formulated worksheet attached.

parting line net pads.jpg click on ref. photo

5.24 All Porosity checks are to be done on all blocks for General Motors jobs. The checks will

consist of polishing the six sides of the steel at the beginning of construction to determine

if porosity is present. Four checks are to be done on the cavity steel after rough cut. Any

indication of porosity is to be communicated to GM through the MINTH Inc. Tooling

Engineer. MINTH Inc. will not be responsible for any cost associated for porosity that has

not been checked for by this procedure.

5.25 Shutoffs are to be a minimum of 6 mm around any part feature on lifter.

5.26 Molds must have parting line locks designed to meet the following:

A minimum of 10 degrees to the line of draw.

Supply good support to counter injection pressures.

5.27 The part must clear all ‘Male’ locks on the core half at full ejection stroke.

Note: The ‘Male’ parting line locks are to be on the cavity side and the ‘Female’ locks on the

core side of mold when ever feasible.

5.28 All molds are to be built with straight side interlocks located at the C/L of all four sides of

the mold. These components are to be made of 8620 steel with a hardness of:

Male – 50 -55 HRC and Female – 55-60 HRC.

Lock sizes are to be as follows:

100- 300 Ton molds – .750” use (DME or equivalent) DME # BGS 2000

310- 950 Ton molds – 1.250” use (DME or equivalent) DME # BGS 3000

1000 - 2500 Ton molds – 2.000” use (DME or equivalent) DME # BGS 5000

5.29 Inserted details utilizing threaded jackscrew holes should be plugged with aluminum or

brass to prevent holes from filling with plastic. If jackscrew holes need to be accessed

frequently, plug with a threaded brass rod with a screwdriver slot or equivalent for removal.

5.30 All molds requiring 250 Tons and up are to be built with hardened steel net pads. These net

pads are to be placed around the perimeter of the mold. The total of the net pads, corner


locks, shutoff around the perimeter of the part and the internal shutoffs are to be designed

to be between XXX and XXX Tons per square inch.

5.31 If the mold is built with net pads that are not recessed then no corner pry slot is required.

5.32 If the mold is built without net pads it must have pry slots on all corners 12 mm high, cut on

45 degree angle and a minimum of 35 mm land from the corner.

5.33 Mold must be capable of lying on 3 sides without damaging tool components, i.e. water

manifolds, hydraulics, electrical connections etc... The use of extended clamp plates is the

preferred means of protection. When extended plates are not practical and when approved

by MINTH Inc. pillar style stand-offs may be used.

stand on an side without damaging components.JPG click on ref. photo

5.34 Pillar style stand-offs are to be mounted into a 1” deep counter bore with a slip fit of no

more than a 0.010 inch.

Ref. Fig. 5.34 Schematic FIG 5.34 Pillar standoffs.pdf Click on pdf.

5.35 For molds 300 Tons and lower the extended clamp plates are to have slots for clamping; for

molds 350 Tons and higher, the extended clamp plates are to have holes matching the bolt

pattern for the designated press.

5.36 Molds shall be equipped with a minimum of 2 safety straps painted red for molds 750 Tons

and below. Molds are to have 4 Safety straps for molds of 800 Tons an up. Threaded holes

are to be provided to hold straps out of the way when not in use.

saftey straps.JPG click on ref. photo

5.37 Eyebolt holes are to be located on the top and two sides of the cavity and core, and must

accommodate the level hanging of mold, both together and separately.

5.38 Ejector plates, clamp plates, and rails are to have eyebolt holes on four sides to

accommodate level hanging.

5.39 For any molds built for 700 Ton machines and up are to have four eye bolt holes in the face

of the cavity and core clamp plates for handling. The eye bolts are to be positioned

approximately at the four corners of the cavity or core block.

four eye bolts.jpg click on ref. photo

5.40 All exposed sharp edges of mold base; ejector plates, manifold etc. are to be machine

chamfered.

5.41 NO WELD SHALL BE USED in the construction of molds without written authorization from

the MINTH Inc. / Minth Tooling Engineer. When welding is authorized, the area of weld

must be shown on a schematic or drawing of mold. This STD applies too, doing and


quoting, all Engineering changes. MINTH Inc. will not be responsible for any cost

associated with unauthorized weld.

5.42 When welding is done to a mold, it shall be done in accordance with the steel

manufacturers guidelines. Certification from the welding source must be provided for any

welding done to a mold.

5.43 All molds shall have individual plaques showing the following:

All plaques are to be placed on the Non-operator side.*

All plaques are to be shown in design.

Water system

Electrical system

Hydraulic system

*Mold opening sequence. 2 plaques

o Mold open sequence is to have a plaque on both non-operator and operator side.

5.44 All molds are be marked with the following information:

Part Name.

Part Number.

Property of: Ford, General Motors Corp., Chrysler etc.

Ejector stroke length.

Total Mold weight.

Cavity weight. Cavity weight must be painted on two sides of the mold in 2” white

letters.

Core weight. Cavity weight must be painted on two sides of the mold in 2” white

letters.

Overall mold dimensions.

Mold opening sequence.

Tooling source name & job number.

Top of mold.

An arrow with the word “UP” above it is to be etched on both sides of the

mold. Ref. Fig. 5.44 Schematic FIG 5.44 Mold identification.pdf Click on pdf.

Texture type and gloss level.

Shrink factor.

5.45 All identification must be etched or machine scribe into the mold. Hand stamping is not

permissible.

5.46 Location of the part identification below is to be submitted for approval to the MINTH Inc.

/ Minth Tooling Engineer and shall be shown in design. written authorization

5.47 Part identification information should be done in a manner that is visible and without the

detriment of tool function or class “A” part appearance.

5.48 For Date wheels required unless otherwise authorized. Use 12mm round Insert indexable

type as follows:

12 Month (outer) / Year w/arrow,


Day.

Shift Schematic FIG 5.48 Date Wheels.pdf .

5.49 Part identification must provide the following information:

The use of an etched date grid requires authorization.

Logo: Minth.

Customer Logo: Ford, Chrysler, General Motors Corp., etc.

Part Name.

Part Number.

Material ID.

Date stamp: Round insert type with year, month, day and shift are required.

Grid type 12 months by 4 years.

o Monthly grid box is to be no less than 3mm square.

Grid type must be approved by the plant.

Recycle code. (Three arrow triangle) or < mat’l >

Cavity number.

RH or LH (if handed part).

5.50 All eccentric, angled, or otherwise non-symmetrical core pins must be keyed by means of a flat

on the core pin, into a rectangular pocket in the retainer plate.

5.51 All ejector pins and core pins must be neatly and legibly numbered on the print and heads with

corresponding identification in the retaining plate for ease of assembly.

Click on ref. photo.

5.52 All threaded items susceptible to loosening must be secured it place using NYLOCK or equivalent

(shown in bill of materials) or jam locking devices shown on drawing in detail.

5.53 Screw threads are to be engaged a minimum of 1.5 X and a maximum of 2.5 X the diameter of

the bolt.

5.54 Guide pins are to have a 15 degree lead in the depth of at least the diameter of the pin for molds

of a 750 Tons and up. The full pin diameter must be engaged at least 1.0 in. prior to any parting

line locks, horn pins, heal blocks or mold components are engaged.

Ref. Fig. 5.54 Schematic FIG 5.54 Guide Pins.pdf Click on pdf.

5.55 The zero corner Guide pin must be off-set in one direction so the mold cannot be assembled

incorrectly. Use .25”; 6.35mm for molds of 300 Tons and smaller and .625” 15.875mm for molds

350 Tons and larger.

5.56 Guide pin pockets must be vented utilizing a 45 degree dump slot to outside of mold.

J F M A M J J A S O N D

15

16

17

18

ejector pins numbered.JPG


5.57 Guide pin bushings are to be bronze and serviceable from within the press. Steel bushing may be

used if the diagonal distance between the bushings is less the 24.0 inches.

5.58 Guide pins can be a flanged through type or a straight shaft.

5.59 Guide pins are to be positively locked in the cover half with a set screw and an anti-back out set

screw. The shaft of the pin is to have a flat to accept the set screw. Ref. Fig. 5.54 in 5.56

5.60 All guide pins that are not flanged through type are to have an access hole for knock out.

Ref. Fig. 5.54 in 5.56

5.61 All shutoff angles are to be at a minimum of 7 degrees. Should conditions require less than 7

degrees shutoff angle, written authorization is required.

5.62 All shutoff angles less than 7 degrees are to be reported to the MINTH North American Tooling

Engineer. Each position is to be shown in view and section from the mold designs and approved

by the MINTH North American Tooling Engineer.

5.63 Support pillars are to be mounted to the clamp plate not the core block.

Support Pillars.JPG Click on ref. photo

5.64 The support pillars are to be placed as close to the maximum stress points as possible, with

0.002 to 0.003 inch pre-load between the rails and the support pillars of molds 450 Tons and

below and 0.003 to 0.005” on molds 500 Tons and up.

5.65 All internal sliding components are to have an external means of lubrication from an external

fitting. Feature being lubricated are to be stamped next to the fitting.

5.66 All rail parallels must be fastened and located to both the back clamp plate and core block.

Ref. Fig. 5.66 Schematic FIG 5.66 Rails and support pillars.pdf Click on pdf.

5.67 All molds are to be equipped with a flush mounted Progressive Components cycle counter, and

should be mounted on the operator side of mold.

cycle counter.JPG

Click on reference counter

5.68 Molds are to have as many ejector plate knock out holes in the clamp plate as the designated

press dictates and can fit within the rails for the given mold size.

5.69 All molds are to be equipped with swing arm location sensors (Limit switch) on the ejector plate

to acknowledge forward and back positions. “Thin switch” sensors are not to be used.

Ref. Sec. 9.


5.70 Molds for 250 Tons and smaller may use only one limit switch. Molds for 300 Ton and larger are

to have limit switches on both ends of the ejector plate. These switches are to be wired in

parallel.

5.71 Molds using inserted blocks for cavity and core are to have the insert blocks net on three

surfaces; bottom and two adjacent sides.

5.72 The cavity and core blocks are to be bolted to the bottom of the pocket.

5.73 Wedge drivers are to be used to keep the insert blocks net and located into the “0” corner.

Ref. Fig. 5.73Schematic FIG 5.73 Insert wedges.pdf

Click on pdf.

Wedge lock.JPG Click on ref. photo

5.74 The wedge clamp drivers for the cavity or core insert blocks are to have two screws each and are

not to net on the bottom of their respective pockets. Ref. Fig. 5.73

5.75 The mold base pocket is to have a fillet left in the bottom corners.

5.76 The insert blocks are to have a 45 degree chamfer on the bottom edges that is equal to or

greater than the tangent of the fillet in the bottom of the insert pocket.

Ref. Fig. 5.73 Ref. & pdf. In 5.73

5.77 All molds built for glass filled material with a GF content of 25% or are less are to be nitride

coated to depth of .0002” depth.

5.78 All molds built for a glass filled material with a GF content of 30% or greater are to be quoted

with H-13 steel insert constructions.

5.79 All molds are to have ejector pin pressure sensors and hookup plug.

Reference the quoting section 1.27

5.80 Steel tolerances are as follows: Unless GD&T specifies otherwise.


For parts 100mm or longer:

General parting line edge cavity size, length width tolerance is .10mm.

Feature size less than 25mm square is .10mm.

Hole true position is .05mm.

Hole feature size in +.10 / - .05mm.

For parts 100mm or Shorter:

General parting line edge cavity size, length width tolerance is .05mm.

Feature size less than 10mm square is .08mm.

Hole true position is .05mm.

Hole feature size in +.08 / - .08mm.

All tolerances are to math data.

VI. Cooling and Water Lines:

6.1 “O” rings are NOT allowed in any water system path. All water must flow through hoses,

stainless steel piping or channels through steel blocks with any connections done with threaded

fittings.

6.2 Water lines must be designed to maximize the mold’s ability to cool the part.

6.3 Water lines must be designed such as to yield even cooling throughout the mold.

6.4 Water manifolds are required on all molds.

6.5 Water systems are to be symmetrical to each cavity in both core and cavity whenever possible.

To supply water to the operator side manifold the use of through lines through the core or cavity

block is permitted.

6.6 Water manifolds are not allowed on the top of mold.

6.7 All slides and lifters etc. must have provisions for effective cooling. Where conventional water

lines cannot be used, the use of bubblers, baffles, thermal pins must be utilized.

6.8 When using water baffles the clearance of the blade hole should be 1.25 times the hole

diameter.

6.9 The baffle blade is to be no less than .004” / .1mm the diameter of the baffle hole.

6.10 Water lines should be no closer than 1.0X the diameter of the water line from part surface and 6

mm minimum from core pins, ejector pins etc. Written authorization is required for deviation.

6.11 Water lines in Core and Cavity steels should be a minimum 14.29 mm (9/16 inch) in diameter

whenever possible. Smaller diameter lines require authorization from the MNA tooling engineer.


6.12 Water fittings and hoses from the manifold to the mold are to be 12.7mm (1/2” inch) minimum.

Water lines.jpg Click on ref. photo

6.13 Water line hose is to be rubber and rated at 2.1 MPa or 300 psi.

water lines rated at 2.1 Mpa - 300psi.jpg Click on Reference photo

6.14 Connections to the water manifold are to be hard plumbed into the manifold. Water manifolds.jpg click on ref. photo

6.15 Connections from the water manifold to the mold are to be quick-disconnect fittings. quick disconnect.JPG click on ref. photo

6.16 Water manifolds should have 1 IN and 1 OUT per side (Core and Cavity); unless a separate

water circuit is done for lifters or slides.

These main fittings to the water manifold are to be ¾ for any press under 700 tons and 1 inch on any press over that”.

The IN fitting is to be a “Male” fitting.

The OUT fitting is to be a “Female” fitting.

Numbered water lines.JPG Click on Ref photo

6.17 All molds must be pressure tested at 80 psi. at the tool source prior to shipment.

6.18 Both main “IN” & “OUT” water connections are to be hard plumbed with both fittings facing the

non operator side of mold or toward the bottom of mold. Fittings facing the bottom of mold need

approval.

6.19 Water fittings part Numbers-

¾ inch fittings Male and Female- BST-6M any press under 1000 ton

1 inch fittings Male and Female- BST-8M 1000 tons and up.

Fig. Schematic 6.16 Schematic FIG. 6.16 Water Main IN & OUT.pdf Click on pdf.

Water manifolds piped to side.JPG Click on Reference photo


6.20 Water manifolds are to be color coded as follows:

Use PPE (Plastic Process Equipment) or equivalent

PPE 300 Series (1/2”) FEMALE fitting for water “OUT” line on the manifold painted RED.

Part numbers PS-300 Non valved.

Use PPE (Plastic Process Equipment) or equivalent

PPE 300 Series (1/2”) Male fitting for water “IN” line on the manifold painted BLUE.

Part number PN-354 NPT for male thread.

Part number PN-354F NPT for female thread.

Schematic FIG 6.19 Water Main IN & OUT.pdf Click on pdf.

6.21 All water line fittings and hoses are to be kept out of clamp slots.

6.22 All hoses connected to traveling components, must be installed so as not to wear during the

function of the mold.

6.23 An 8 ½" x 11" water line schematic is to be included in the Final Mold Design drawings.

6.24 A fluid run-off Slot, approximately .380”X.380”, must be provided if inlets and outlets are placed

on the top of the mold. The fluid run-off slot should run into and down the side of the mold the

full length of the core and cavity block.

6.25 All water line openings other than inlets or outlets must be plugged with brass pipe plugs and

thread sealant.

6.26 Water plugs: A spot face is required for a tapped hole on an angled surface.

6.27 Flow direction of all water circuits must be shown with dashed lines and arrows in design.

6.28 Water line circuits must be numbered; 1 IN,1 OUT; 2 IN, 2 OUT, etc

Ref. Sec. 6.19 water lines marked in & out.JPG Click on Reference photo


6.29 All water fittings are to be brass with the exception of the main piping of the water manifolds.

Galvanized pipe is permissible.

6.30 All molds are to include hoses and fittings to any looping water lines. There should be only one

in and out at the water manifold, unless, it has been determined that the circuit is to be

separated from the manifold and made its own circuit.

6.31 Separate water manifolds and fittings are to be provided for lifters, slides or circuits that need to

become individual circuits and cooled differently from the main mold. It is the vendor’s

responsibility to add these if proper mold function cannot be met.

6.32 When shipping molds all waterlines are to be drained before shipping.

VII. Slides:

7.1 Slides and heel blocks must accommodate a means of lubrication. Self-lubricating (Graphite

impregnated) wear plates are not to be used unless authorized in writing.

7.2 Slides on an angle of 15 degrees or less can be driven by a horn pin.

7.3 Any slides that have an angle greater than 15 degrees are to be driven with a hydraulic cylinder.

7.4 Slides are to be cooled with water whenever possible. If water cannot be accommodated in a

slide it must be authorized by the Minth North American Tooling Engineer.

7.5 All slides are to have grease grooves on the lamina wear surfaces.

Slide wear plates.JPG

Click on reference photo

7.6 All slides are to ride on (¼”) .250” / 6.35mm minimum bronze or Lamina bronze wear plate with

grease grooves.

Hardened steel wear plates are NOT permissible.

Bronze wear surface is to be 180BHn.

7.7 Wear surface on slide for heel block is to have (¼”) .250” / 01steel hardened steel 48Rc to 52Rc

wear plate with grease grooves on wear surface.

Heal block wear plates..JPG


7.8 DME or equivalent “clothes pin style” slide retainers are required on all slides.

7.9 Dowel rod type detents are permissible for slides that travel horizontal in the press.


Ball type detents are not allowed.

7.10 Ejector pins must not be placed under slides.

7.11 Slide length to width ratio should be 1.5 to 1.0 or greater.

7.12 Horn pin angles are not to exceed 15 degrees from line of draw, and should be of adequate

number and size to ensure function.

Ref. Fig. 7.12 Schematic FIG 7.12 Horn Pin & Slide.pdf Click on pdf.

7.13 Horn pin holes are to be machined in the solid cavity insert steel. No secondary piece

construction allowed.

7.14 Horn pin holes should have a .001” (.025mm) to .002” (.05mm) slip fit and keyed for retention

and removal from parting line.

Ref. Fig. 7.14 Schematic FIG 7.14 Horn Pins & Slides.pdf Click on pdf.

7.15 Slides are to be gibed and guided. Gibs are to be a minimum of 12mm thick to be constructed

from Ampco 18 or 21 material.

7.16 The cavity block is to net on the top, heal block and at the parting line of the slide.

7.17 Slides should be removable from within the press and in any position. Eye bolt holes should

allow the slide to be removed from within the press in a horizontal or vertical position.

7.18 Slides weighing over 20 lbs. must have handling hole to facilitate maintenance. These holes

should be left unplugged for shipment.

7.19 For molds built for glass filled materials are to have the part surface treated with nitride coating

to .0002” depth.

VIII. Lifters:

8.1 Any lifters that are too small to have water in them must be made of standard P-20 steel.

8.2 Similar lifters must be designed for Non-inter changeability.

8.3 The minimum rod diameter for angled lifters is 1.0 inch dia. and ¾ inch dia. for straight lifters.

Authorization is required for any rod diameter less than ¾ inches.

8.4 Lifter rod angle should not exceed 15 degrees without Authorization of MINTH Inc. Tooling

Engineer.

8.5 Lifters are to net onto a shoulder of the lifter rod. The minimum shoulder width is .100 inches.


8.6 If the lifter rod is too small to accommodate a shoulder, the rod and the lifter are to net at the

end of the lifter rod in a flat bottom bore.

8.7 Lifters with single rods are to be keyed to prevent turning with a flat on the rod and the bushing

keeper as the anti-rotation stop.

8.8 Lifter heads are to be fastened to lifter rod with a roll pin.

8.9 For lifter rods 7.0 inches and under, the bushing contact surface to lifter rod should be 2 X the

lifter rod diameter. For lifter rods 7.0 inches and longer there should be two bushings with

contact surface of 1 ½ X the lifter rod diameter. No bushing should exceed 2.5 inches in length.

8.10 Lifter rods are to be retained by a self-locking screw to the lifter slide.

8.11 Lifter slide carriers are to be Lamina bronze gibs and wear plates with grease grooves.

8.12 When two bushings are used, the bottom bushing is to be held in place by a keeper that is sub-

flush to the bottom of the core block. The top bushing should be held in place by a round

spacer, leaving a minimum of 1.0 inch below the lifter pocket. The keeper for the bottom

bushing should also serve as the anti rotation guide for the lifter rod.

8.13 Lifter rod bushings are to be Lamina bronze with grease grooves.

8.14 All lifter slides and lifter rod bushings are to have an external means of lubrication with grease

fittings to the exterior of the mold.

8.15 Mold designed with converging lifters are to have provisions to prevent part from traveling with

one set of lifters or the other.

8.16 Lifters weighing over 10 lbs. must have handling hole to facilitate maintenance. These holes

should be left unplugged for shipment.

8.17 The final lifter length is to be etched or engraved into the lifter rod. The stamped area must be

recessed and not pass through the bushing.

8.18 When rectangular lifter rods are used that go through the core block without a bushing they are

to be Nitrided to 1.002” deep.

IX. Ejection:

9.1 All molds are to have guided ejection with pins of appropriate diameter to support the weight

of the ejector plate.


9.2 A minimum of 4 ejector plate Guide Pins are required and when possible Mechanical Springs

are required.

9.3 Guided ejection pins must be mounted through the clamp plate.

9.4 Guided ejection pins are to extend into core half a minimum depth equal to the pin diameter

up to a maximum depth of 30mm.

9.5 Guided ejection pins are to have a slip fit of the following:

.15 mm from 0 to 400mm from C/L of mold.

.2mm from 400 to 800mm from C/L of mold.

If Guided ejector pins are greater than 800mm form C/L an additional set of pins are to

be added at the C/L with a slip fit of .1mm.

9.6 For guided ejection pin bushings utilize bronze bushings with grease grooves in the ejector

plate. These bushings are to have a hole through the bushing to allow external means of

lubrication. Bushing with Grease grooves.JPG

Click on Ref. photo

9.7 Ejector plate system must be enclosed. The covers are to be made of a metal plate and be

easily removed. The metal cover plate is to be painted yellow.

9.8 All molds are to have a minimum of 4 return pins for the ejector system.

9.9 All molds are to have ejector plate stop buttons directly in line with the return pins and

throughout the ejector plate to insure adequate support. Round 1 inch diameter buttons

preferred where possible.

9.10 When accelerated ejection is used, a positive return system is required.

9.11 Maximum span between return pins shall not exceed 24 inches without authorization from the

Minth NA Tooling Engineer.

9.12 Return pins are to be pre-loaded 0.001 inches to 0.003 inches.

9.13 All bushings must have an external means of lubrication with grease grooves.

Guided ejection bushings.

Lifter bushings.

Leader Pin bushings.

9.14 Ejector pin diameters should be as large as possible and are to approved by the Minth NA

Tooling Engineer.

9.15 Use sleeve ejection on all molded bosses, cored locator pins etc. Using standard D.M.E. or

equivalent.


9.16 Tooling source is to provide at least 2 Spare Sleeves if they are not “Off the Shelf” items.

9.17 All ejector pins are to be flush to core surface.

9.18 All ejector pin holes require a minimum of 18 mm of bearing surface.

9.19 Parting line ejection must be approved by Minth NA Tooling Engineer.

9.20 Molds must be designed so the part being molded will clear all mold components; parting line

locks, slides, lifters, etc. at full ejection stroke.

9.21 The mold is to be designed so that the part is held at full ejection to insure consistent location

for robotic extraction but not interfere with the robotic extraction of the part.

9.22 The mold is to have a minimum of 4 replaceable knock out “pucks” mounted to the ejector

plate. The “puck” is to be mounted to the ejector plate approximately .020” / .5mm sub-flush

to the back of the clamp plate using 4 cap screws.

Ref. Fig. 9.22 Schematic FIG 9.22 Threaded Knock Out Pucks.pdf Click on pdf. Ejector plate pucks.JPG Click on ref. photo

9.23 Pucks are to be manufactured from P-20 steel. 28 to 32 Rc.

9.24 Puck diameters are to be as follows. Off the shelf PCS

1.77” – 45.0mm for molds 250 Ton and below.

2.0” – 50.0mm for molds 300 Ton to 650 Tons.

2.75” – 70.0mm for molds 700 Tons and up.

9.25 The knock-out threaded size for the center of the puck is to be supplied by the production

plant. Reference photo in section 9.22

9.26 All molds are to be equipped with swing arm location sensors (Limit switch) on the ejector

plate to acknowledge forward and back positions. “Thin switch” sensors are not to be used.

Use Allen Bradley limit switch 802T-A with actuator arm 802T-W1A. The Limit Plug to be Han16

Pin by Harting

9.27 Molds for 200 Tons and smaller may use only one limit switch for the ejector plate. Molds for

250 Tons and larger are to have limit switches on both ends of the ejector plate. These

switches are to be wired in series.

9.28 The ejector plate is to have adjustable stops that are mounted to the ejector plate that can

actuate the limit switch. Wiring to the Han16 Plug to be as shown below- Limit switch adjustable stops.JPG click on reference photo.

EU13_v1_5 (1).pdf

9.29 Limit switch mounting brackets are to be made of ¼” steel and mounted to the core plate

with cap screws.


9.30 Ejector plates driven with hydraulic cylinders are to have:

a) A “U” channeled collar that goes onto the rod shaft of the cylinder.

b) The rod shaft is to have a flat to accept a key to prevent turning.

c) The collar is to have a key to prevent turning.

d) The ejector plate is to have a “T” slot milled into it to accept the collar.

e) The collar is to go past the ejector plate the thickness of the stop bottoms.

f) The collar is to net on the clamp plate.

Ref. Fig. 9.30 Schematic FIG 9.30 Hyd ejection.pdf Click on pdf. Hydraulic Ejection.jpg click on ref. photo

X. Gates & Runners:

10.1 In multi-cavity molds; gates and runners must be designed to provide a balanced / uniform fill

of all cavities. Ref. 10.2

10.2 Gate placement and flow lengths are to be based on the flow length chart for the given

material.

10.3 All gating and runner configuration are to be based on a mold filling analysis. Cost for analysis

is to be line itemed on the vendor quote.

10.4 Gates and runners must provide adequate cavity fill / pressure, using generally accepted

molding parameters.

10.5 Full round runners are to be used whenever possible. Trapezoidal runners are permissible

when a “Tunnel slide” is used. The trapezoid is to have uniform diameter cross section

throughout the length of the runner.

10.6 A short shot series of a minimum of 5 shot shots to verify balanced fill pattern each cavity or

cavities is to be provided to the MINTH NA Tooling Engineer.

10.7 Adjustments in gate and runners, necessary to provide a balanced fill and acceptable molding

pressures shall be done at no cost to MINTH NA. All gating and runner changes must be

updated in mold design.

10.8 The rerouting or moving of runners and gates that differ from the original design will be

considered an engineering change and will be quoted as such.

10.9 Subgates shall be at no more than 45 degree angle to surface.

10.10 All subgates are to have a “C” shaped runner to the gate. The cold slug well is to go past the

gate 1.5 times the runner diameter. The cold slug should be angled away form the part at a

minimum of 30 degrees.

10.11 All Soft Shot Cashew gates are to be built with a .040 diameter at the tip.


10.12 Use “S” shape runners are to be used with edge gates and have a cold slug well to go past the

gate 1.5 times the runner diameter.

10.13 “Sucker Pins / Sprue puller pins” must be provided directly next to each nozzle tip and must be

no larger than the runner diameter.

10.14 A sprue puller well is to be provided under each nozzle tip. This well is to have a negative draft

of 5 degrees and a depth 1.5 times the runner diameter.

10.15 Cold slug wells are to be used at any point in the runner system where flow direction changes

10.16 Length of cold slug is to be a minimum of 1.5 times the runner diameter.

10.17 A cold slug well must be located within 3 inches of where the runner enters the cavity.

10.18 Runner system should have all directional change corners generously radiused to reduce shear.

10.19 Vents are to be machined in the runner system at all directional change corners and cold slug

wells.

10.20 Gates and runners must be detailed and dimensioned on the print.

10.21 Subgates for abrasive materials must be inserted with hardened steel 50Rc or plated to a

minimum of 50Rc. Abrasive materials are those with any filler content of more than10% for

mineral and talc and 5% for glass.

10.22 Subgate shear rate in mold flow for most molded in color materials are not to exceed 75psi.

Subgates for chrome parts are not to exceed a shear rate of 12,000psi/rs or a shear stress of

.3MPa.

Ref. section 17.7 and 17.8

XI. Hot Runner Manifolds:

11.1 All hot runner manifolds are to be built by Incoe or Synventive for injection molds built for

North America.

INCOE®

Synventive

11.2 Yudo Manifolds are not to be used in molds shipped to North American.

11.3 Manifolds designed must be based on mold flow analysis and yield an even uninterrupted flow

of material capable of maintaining uniform temperature throughout the resin melt stream.


11.4 Manifold suppliers are responsible for the manifold design which includes all requirements

within these standards.

11.5 Hydraulic Hook ups are to be H3 on the valve gates in presses below 1000 Ton and H4 on 1000

tons and up.

11.6 All heaters shall be rated for 220-240 volt single-phase operation.

11.7 All heaters and thermocouple zones shall be stamped next to the plugs, on the plugs, and on

the outside of the Electrical Box.

11.8 All wires from heaters shall be placed in a fully enclosed channel, accessible from outside the

mold. There shall be no sharp edges or corners to potentially cut or damage wiring. Unitized Manifold.jpg click on ref. photo

11.9 Manifolds will be wired using the following:

Heater:

a. Epic heater; H-BS series, plug # 10.1700 (x2) for Male.

b. Use panel mount base 10.1320

c. DME style heater, power Series D, 10 amp (12 zones) 25 position plug. plug # FC 325/MC

425

Thermocouple:

a. Epic thermocouple; H-BE series #10.1950 for Female.

b. Use panel mount base 10.0729 for 16 Pin.

c. Use panel mount base 10.0720-01 for 32 Pin.

d. DME style thermocouple 16 amp (12 zone), 24 position + ground FS 124/MS 224

heater and thermal couple plugs.jpg click on ref. photo

11.10 All electrical connectors are to be mounted in a JIC-approved electrical box or mounted onto a

hinged plate recessed into the mold.

11.11 If recess style is used, the electrical connectors are to be mounted to a hinged plate for ease of

access. Adequate cooling of this area must be provided to ensure wiring does not over heat.

11.12 Splicing of thermocouple or heater zone wiring is not permitted.

11.13 The electrical connections are to be located on the top or opposite the operator Side of the

mold.

11.14 Hot runner manifolds and nozzles are to have the following designations:

Nozzles are to be designated numerically with the letter “N” preceding the number. Example:

N1, N2, N3, etc.


Manifold zones are to be designated numerically with the letter “M” preceding the number.

Example M1, M2, M3, etc.

In numbering hot runners systems, all nozzles will be numbered first, followed by the zones in

the manifold.

Each manifold zone and nozzle shall have one thermocouple. These are to be designated

numerically with the letter “T1, T2, T3” preceding the number. The numbers are to be

coordinated to the respective zones.

11.15 There may be a maximum of three control zones on a single nozzle. Tip, middle and back. The

tip and back zone will be controlled independently and the middle can be wired in parallel and

controlled as one zone.

11.16 The nozzle and manifold zone numbers are to be stamped on the following surfaces.

a. Nozzle flange,

b. On the back of the cavity next to the nozzle

c. On the manifold.

11.17 Manifolds must have support pillars opposite the machine nozzle seat, drops and or gates.

11.18 For expansion purposes any locators or dowels should be on the centerline of the manifold

horizontally and vertically.

11.19 Jack screw holes will be required in the manifold near the sprue and at each leg of the manifold

to assist in removal. (Two at each location.)

11.20 All cartridge and heater bands must be “Off the Shelf” items.

11.21 All manifold systems must be “Unitized”. A unitized system is a manifold system that is complete

with manifold, hydraulics, wired plugs and channel system to protect wiring as one unit.

Unitized hot runner system.jpg


11.22 A metal tag shall be permanently affixed on the operator side of the mold, showing: an electrical

diagram of the hot runner, zones, heaters and amp draw. manifold plaque.jpg Click on ref. photo

11.23 Each mold design utilizing a hot runner of more than 1 zone is to have a separate thermocouple.

11.24 8 ½” x 11” sheet, showing in reduced scale the manifold layout and zoning. Heater cartridges

are to be labeled with Size and Wattage.

11.25 Sufficient clearance must be shown for wires around the mold components.

11.26 For hot sprues with one or two zones; use D.M.E. Plug # CKMINTHC-1. Use one plug per zone.


11.27 All valve gate pins are to be driven hydraulically.

11.28 All Class A Parts are to have a Valve Pin control unit with Synflow as the preferred style. No

additional costs can be charge to Minth to run in production.

11.29 Some Presses require valve gate pins are to be controlled with oil valve solenoids that are

mounted to the mold. See Press Specs below. Valvegate solenoid.jpg click on ref. photo

11.30 All plumbing and components are to be inside the base clamp plate of the mold for protection

unless otherwise authorized.

11.31 No oil lines are to be visible through the back plate of the mold. Valve gate hydraulic lines are

to be covered by the clamp plate.

11.32 All oil lines going to the valve gate heads are to be rated at 700 degrees Fahrenheit and 3000

psi.

XII. Venting:

12.1 Vents are to be shown in design.

12.2 It is the responsibility of the mold builder to provide adequate venting to allow gases to escape

from the cavity. Special attention should be given to the last places to fill, knit areas, end of

runner cold slugs, and deep or dead-end pockets. Inserts or pins should be used for ribs or

hard to fill details.

12.3 As a general rule, vents should be machined at a maximum spacing of 50 mm, x 12 mm wide

and with a land area no greater than 2 mm from the parting lines.

12.4 All vents must be machined to extend to the outside of the mold. Evacuation channels must be

a minimum of .030 inches deep. Evacuation channels should allow gases to exit the mold

without creating any back pressure.

12.5 Additional venting may be required based on first run observations and cavity fill patterns.

Vendor should factor in cost for rework of tool when quoting.

12.6 Vent relief channels are to machined in were ever possible for the purpose of adding venting

when and were needed.

12.7 All venting and vent relief channels are to be identified and shown in the Preliminary design.

12.8 All venting is to be surfaced in math data.


XIII. Locating Rings & Sprue Bushings:

13.1 Locating Rings are called out below in each press.

13.2 Sprue Bushing are called out below in each press.

13.3 Sprue bushings are to be keyed to prevent turning.

13.4 No gap allowed between sprue bushing and locating ring.

13.5 The mold is to be equipped with a collar between the locating ring and sprue bushing to

prevent “plastic drool” from getting into the manifold cavity.

13.6 The locating ring is to be reversible to accommodate use with a magnetic platen or other

presses.

Ref. Fig. 13.6 Click of pdf.

13.7 Reference sections XVIII & XVIX for vertical press criteria.

13.8 Valvgate Solenoid are to mold mounted and 24DC.

XIV. Texturing:

14.1 Tenibac Graphion or Mold Tech are the only texture vendors permitted.

14.2 It is the Tooling sources responsibility to manage the texturing source until a signed AAR

approval is achieved.

14.3 Draft angles on textured surfaces should be a minimum of 1 degree per each 0.001 inches depth

of grain. Amount of draft depends on whether angle is Inside, outside, type of grain, wall

thickness, and material.

14.4 MINTH Inc. will specify texture / grain source at time of graining.

14.5 Prior to Texturing / Graining the following must take place:

Pre-grain approval will be required from the MINTH Tooling Engineer.

Parts are to be submitted to the OEM through the MINTH / Starboard Tooling Engineer.

Upon approval a diagram of all pre-approved welded areas must be provided to MINTH Inc.

Tooling Engineer, as well as the graining source.

14.6 MINTH Inc. will not be responsible for any cost associated with unauthorized weld.


14.5 The Texture / grain source vendor is responsible for the graining source and achieving an

approved AAR from the OEM.

XV. Hydraulics:

15.1 “O” rings are NOT allowed in any oil system path. All oil must flow through oil hoses, channels

through steel blocks with any connections done with threaded fittings.

15.2 Parker or Miller, hydraulic cylinders are to be used.

15.3 All oil lines are to be rated for 700 degrees Fahrenheit / 371 Celsius and 3000 psi minimum.

15.4 All oil line hose fittings are to be the “crimped” style. Hydraulic hose fitting crimp style.jpg

Click on reference picture

15.5 Hydraulic cylinder size must be based on a 2150 psi maximum line pressure for pressure

calculations.

15.6 All hydraulic manifolds are to be installed on the bottom of the mold whenever possible.

15.7 On hydraulic manifolds the center line distance between fittings are to be a minimum of

60.0mm.

15.8 Designs that require cylinders to withstand cavity pressures must be avoided; self locking

cylinders or a secondary locking feature must be used.

15.9 All hydraulic fittings are to utilize standard straight pipe threads with compression seals for

use with:

Parker 60 series H4-62 Female Connectors “SET”

Parker 60 series H4-63 Male Connectors for “PULL”

15.10 Hydraulic cylinders are to have swing arm style position sensor switches.

Use Allen Bradley limit switch 802T-A with actuator arm 802T-W1A

15.11 For position sensor switch electrical connections use:

Use Han16 Harting Plug

15.12 Limit switches must be wired in series, both “Pull” and “Set” circuits:

For Milacron/KM Presses

o “SET” is Back.

o “Pull” is Forward.

For Our Ingle Presses (300 Ton vertical)

o “SET” is Forward.


o “Pull” is Back.

15.13 Molds using more than one cylinder to do the same function must have flow controls and

manifold.

15.14 When using a cylinder manifold, only two connections are permissible.

15.15 An 8 ½” X 11” schematic showing Layout and Zoning of the hydraulic system is to be included

in Final Mold Design Drawings.

15.16 Any hydraulic lines or cylinders mounted on the top of the mold must be accompanied by a

3/8in. X 3/8in. drain channel between the fitting and cavity edge of mold that flows into a flow

channel that goes down the side of the mold the full length of the block.

15.17 When hydraulic cylinders are used to drive a multi core pin plate, the plate is to be guided by

4 guide rods with bushings.

15.18 All cylinders are to be cushioned unless authorized by the Minth / MINTH tooling engineer.

XVI. Prototype

16.1 Prototype molds are to be 1040 or P-20 “Soft Steel”.

16.2 Aluminum molds will require approval of the MINTH Inc. tooling engineer.

16.3 Prototype molds are to be flash free dimensionally correct molds. The vendor is responsible

for flash free parts. No pc price will be accepted for trimming.

16.4 Lifters do not have to run automatic or be tied into the ejector system, unless the mold is

specified for more than 250.shots. Unless otherwise specified, molds are to be quoted

assuming more than 250 shots.

16.5 Lifters can be made as rod less inserts, if the mold has been specified for less than 75 pieces

16.6 If the lifter rods are not tied into the ejector plate, the rod end must have a balled end or heal

to slide against the ejector plat during ejection.

16.7 The gate area for PVC prototype molds is to be done with an insert in both the core and cavity.

The cost for changing both inserts to another iteration of gate is to be factored in.

16.8 Prototype molds do not require water manifolds.

16.9 Prototype molds do not require mold qualification as outlined in section XVI.


16.10 Prototype molds are to be quoted with two tryouts. Each molding trial is to be for a minimum

of 200 sets of good parts.

16.11 Vendor is responsible to ship all good parts to whichever MINTH Inc. plant has that work,

either Tawas whichever applies. Assume farthest plant if not specified.

XVII. Mold Requirements for Chrome Parts.

Product Design: (For Chrome)

17.1 Any parting lines on a class “A” surface will have the core surface sub-flush to the cavity by

.005” or .12mm.

17.2 All parting line surfaces will be open to the line of draw by 5 degrees. 3 degrees is the

absolute minimum.

17.3 In the case of a grille mesh, the opening must have 5 degrees draft on any vertical surfaces

outside of 12.0” from C/L. 3 degree draft will only be accepted on surfaces outside of 12.0”

from C/L if it is on a 40 degree angle or greater.

17.4 Any parting line surface that is less than 78 degrees to the line of draw will have a 1mm flat

that is no less than 5 degrees open to the line of draw and no more than 78 degrees open to

the line of draw.

17.5 All parting line edges require a .5mm X .5mm energy robber notch around the entire edge of

the part. The inner edge of the notch is to have a radii. This can be achieved in another

manor by creating a bead that is 1.0 wide starting at the inner edge of the .5mm notch.

Gating: (For Chrome)

17.6 All gating will have a flow length that meets or exceeds the requirements as outlined in the

flow length chart in these standards. This flow length chart outlines the flow length to be used

based on the material, nominal wall thickness and type of gating.

Ref. Fig. 17.6 Flow length chart. Schematic FIG 17.6

Flow Length Chart.pdf Click on pdf.

17.7 Gates or part fill is not to exceed a shear flow rate of 12,000psi/rs in mold flow.

17.8 Gates or part fill is not to exceed a shear stress of 3.0 MaP.

Venting: (For Chrome)

17.9 All molds are to be vented in accordance to the requirements outlined in section XII.


17.10 If two flow fronts are shown to come together on a parting line edge, Porcerax II inserts or

pins can be used in the core to enhance degassing.

17.11 All core details on the part are to have vents in the lifter or slide that allow the detail to fill

easily. These vents are to go down into the pocket of the lifter or slide and through the core.

Processing: (For Chrome)

17.12 Molds are to be processed within the parameters outlined by the manufacturer of the polymer

being used for an injection molding process.

17.13 Mold temperatures should fall into the range as outlined in the processing chart in these

standards. If it is necessary to use processing parameters that are outside of the chart it is to

have written authorization from the manufacturer of the polymer.

17.14 Material melt temperatures are start at the lower end of the recommended range to prevent

unnecessary introduction of heat to the overall system. Processes are to be validated with

chrome adhesion testing.

General Construction: (For Chrome)

17.18 The mold cavity surfaces are to be polished to a SPI A-3 #15 diamond polish.

XVIII. Dual Shot Molds:

18.1 Vendor is responsible for coordination of fit of all shutoffs between the substrate (Hard Shot)

mold and the second shot (Soft Shot) mold.

18.2 The vendor is responsible to produce a cosmetically acceptable part.

18.3 All Clamp plates for dual shot molds are to be 1.25 inches thick.

18.4 If the second shot mold is designed to run in the 300 Ton vertical press then the stationary

clamp plate is to have notch relief’s as follows as outlined in Figure 20.5 300T vertical plate

notch:

12 inches from C/L of mold horizontally.

14 inches from C/L of mold vertically.

Ref. Fig 20.5 Schematic FIG 20.5 300T Vert clamp plate notch.pdfClick on pdf.

18.5 If the First shot (Hard shot) mold is built to run in the 450 Ton press and the cavity block is

wider than the supplementary lead blocks, clearance may be needed in the side of the cavity

block.

Ref. Horizontal locator block system schematic.


18.6 The locator ring is to be made reversible.

Minth North American injection press specifications.

IJ42 250 KM Horizontal Presses:

19.1 Molds Use ¾” spherical radius for nozzles.

19.2 All mold built for the 250 ton press are to be built for a drop in load. Top of the mold is the

short side.

19.3 The clamp plates are to be 1.250” thick or 31.75mm.

19.4 Hydraulic Valve gates with Individual hook ups are required.

19.5 Reversible locating ring required with a 3.99 and 4.99.

KM 250T Platen Drawing.pdf

IJ10 /14/17/18 450 Ton Horizontal Press:

21.1 Use ¾” spherical radius for nozzles.

21.2 All mold built for the 450 ton press are to be built for a drop in load. Top of the mold is the

short side.



21.5 Solenoids are required on the valve gates for all 450 ton presses

21.6 The mold clamp plate on the stationary side only is to be notched for the mold locator bracket.

Ref. Fig. 21.5 Schematic FIG 21.5 450 T locator block.pdf Click on pdf.

21.7 Press specifications.

Magna T 450 press specs.pdf click on pdf.

IJ36 580 Ton Horizontal Press:



22.2 All mold built for the 580 ton press are to be built for a side horizontal load. Top of the mold

is the long horizontal side.



22.5 Solenoids are required on the valve gates.


22.7 Press Specification.

MM580WP_SPECS.pdf click on pdf.

IJ40 610 Ton Milacron Press:


23.2 ¾ spherical rad on the tool

23.3 Solenoids are required to run the Valve gate Pins.

23.4 Press specifications-

E400-610.PDF








MM725_SPECS.pdf click on pdf.




25.2 Reversible Locating ring required with 3.99 and 4.99.





MM950specs.pdf click on pdf.

IJ33 1500 Ton Ube Horizontal Press:


26.2 Reversible Locating ring required with a 3.99 and a 4.99.

26.3 Solenoids are required to run Hydraulic Valve gates.

26.4 The clamp plates are to be 80mm thick.

26.5 The electrical plugs are to be mounted on the operator side of the mold.

26.6 The mold clamp plate or its components are not to exceed vertical tie bar dimension of

51.500”.

26.7 A 100mm diameter area of mold steel needs to cover a the magnetic platen sensor centered at

the following dimensions:

Moveable platen: At vertical center line of press and 110mm above horizontal machine

center line.

Stationary platen: At vertical center line of press and 150mm above horizontal machine

center line.


PTI Ube Used UM1500.pdf

click on pdf.

IJ38 1500T Milicron Horizontal Press:





27.4 The clamp plates are to be 80mm thick.

27.5 The clamp plates are to have a rail bolted to the bottom edge that is 80mm X 78mm thick.

27.6 Between the rail and the clamp plate there is to be a .250” thick spacer plate that is notched

around the bolts of the rail so that it can be removed by loosening the bolts of the rail.


10408472.pdf

IJ41 2350 Haitian Horizontal Press: 28.1 Spherical Rad required is ¾ on the tool.


28.3 Reversible locating ring required with a 3.99 and 4.99

28.4 Press specifications. Haitian JU2100.pdf

IJ46 506 KM Horizontal Press. 29.1 Spherical rad is .750



29.4 Press Specifications.

506_Ton 167507-37-01-KM 451-2140 GX_08-23-2019.pdf

IJ45/9 3000 KM Horizontal Press. 30.1 Spherical rad on the tool is ¾

30.2 Reversible locating ring required with a 4.99 and a flat for the platen.



30.4 Press only has 16 zones if more zones are required PTI personal needs to approve.


167507-22-01-KM 2700-12000 MX_08-16-2019.pdf

IJ43 550 KM Rotary 2 Shot Horizontal Press. 31.1 Core water to be plumbed for Operator and Non Operator side. Cavity Water to be

Ran Bottom of Mold.

31.2 Water Plugs on core half are Prod by .500 inches and the limit plugs require notches

on the clamp plate



KM550GXZ_Vorab WAM_Rev1.pdf

IJ44 1300 KM Rotary 2 Shot Horizontal Press. 32.1 Core water to be plumbed for Operator and Non Operator side. Cavity Water to be

Ran Bottom of Mold.

32.2 Hydraulic Valve gates with Individual hook ups are required under 16 zones.

32.3 Limits and oil hook ups are on the moveable platen and need to be slotted.


KM1300MXZ_Vorab WAM_Rev1.pdf

IJ47/8 1850 KM Rotary 2 Shot Horizontal Press. 33.1 Core water to be plumbed for Operator and Non Operator side. Cavity Water to be

Ran Bottom of Mold.



33.3 Press Specifications. Preliminary_KM1800-

3000-1400 MXZ.pdf

XIX Mold Filling and Integrated Warp Analysis.

34.1 All molded components are to have a mold filling analysis, cooling with an integrated warp

analysis as part of the mold design process.

35.1 Meshing

All mesh models for Moldflow must follow Autodesk Moldflow guidelines.

Mid-Plan mesh models are preferred over dual domain.

Dual-Domain models should only be used as last resort. For large complex parts, it is nearly

impossible to achieve an adequate mesh model when using Dual Domain meshing.

3D mesh models must be used when part’s thickness to length ratio exceeds 3:1.

35.2 Gate locations

Node Cone gates should not be used for Moldflow as they do not provide accurate

representation of a gate and gate dimensions cannot be defined with Node Cone gate.

Flow lengths for gates must be in agreement with the Flow Length Chart provided in the

Minth NA Tooling Standards.

Gate land must have at least 3 beam elements to get most accurate prediction of Shear

Rate.

For final Moldflow, All gate locations must match the gate locations provided in the

Mold design.

For final Moldflow, All gate dimensions must match the gate dimensions provided in the

Mold design.

35.3 Material


For Mid-plane and Dual Domain models, CRIMS data is required to simulate accurate warp

results. Material without the CRIMS will provide accurate Warp trend but however the

magnitude of Warp may not be correct.

Materials without the CRIMS data should not be used for warp analysis.

If CRIMS is not available, 3D Mesh type is recommended to run the analysis. 3D solver does

not require CRIMS.

35.4 Moldflow Report

Moldflow report must include the following:

o CAD Data Release Level

Filename

Release level

o Meh Statistics

Type of mesh used

Max aspect Ratio

Mesh match Ratio

Reciprocal mesh match ratio

Nominal part thickness

o Material Information

Manufacturer

Tradename

Recommended processing conditions

Date when the material was tested.

Date when material was tested for CRIMS, if CRIMS is available.

o Gating information


Detailed sketch of gate showing gate type, gate size, runner size,

Drop sizes. Example shown

below

Drops layout showing drop location with distance between each drop.

Example shown below

Type of manifold system ( SVG or non SVG)

o Fill Pattern

o Pressure at Transfer

o Weld Lines

o Air Traps

o Temperature at Flow front


o Shear Stress

o Shear Rate

Shear rate XY plot showing Shear Rate at each gate location

o Volumetric Shrinkage

o Frozen Layer fraction

o Pressure at injection location Plot.

o Clamp force plot

o Deflection – All Effects

o Deflection – X Direction

o Deflection – Y Direction

o Deflection – Z Direction

o Circuit coolant Temperature

o Circuit heat removal efficiency

o Part Temperature

o Core Steel Temperature

o Cavity Steel Temperature

o Recommended Baseline process settings


XX Vendor Contractual Agreement:

36.1 A BAILMENT agreement must be in place for all contracted tools, gauges, fixtures,

machinery and equipment .

These Terms and Conditions can be found at http://www.minthamericas.com/terms-

and-conditions-contracts-all-americas-locations/.

36.2 All contracted tools, gauges, fixtures, machinery and equipment must comply with OSHA

Federal Safety Standards. It will be the vendor’s responsibility to stay informed to the latest

revisions in federal safety standards.

36.3 All contracted tools, gauges, fixtures, machinery and equipment must comply with Minth

Americas published construction and manufacturing standards. It is the responsibility of the

supplier to visit MinthAmericas.com for the latest standards. Supplier shall reference the

standard in which any contracted tools, gauges, fixtures, machinery and equipment complies

with and was constructed in accordance with, on all communications, tagging and labeling.

36.4 All tool designs, surface development, math data, cutter path, tool build, or machining

information are the property of Minth North America and should not (in total or in part) be

given or shared with another company, or duplicated without written approval of MNA. This

information whether created expressly for, or used indirectly for the manufacture of MNA

tooling, shall become the sole property of Minth North America.

36.5 Design approval must be obtained by a Minth North Americas Tooling Engineer for any new

tooling design prior to the start of manufacturing, construction or build. This design approval

constitutes only a concurrence in the general design layout, or function. Design approval does

not constitute approval of design details, or adequacy of such design, strength, and durability

of components and the ability to achieve performance in accordance with requirements,

remains solely with the supplier. If the subject parts cannot be made according to an

approved tool design, the necessary corrections to the tool will be made at the supplier’s

expense.

36.6 The Supplier shall construct and design All contracted tools, gauges, fixtures, machinery and

equipment so it is capable to produce parts or function in accordance to the described

Click on icon

http://www.minthamericas.com/terms-and-conditions-contracts-all-americas-locations/

http://www.minthamericas.com/terms-and-conditions-contracts-all-americas-locations/


specifications and scope of work. These specifications and scope of work include however are

not limited to; dimensional, visual, GD & T, functional, appearance and program quantity

specifications. The supplier will be responsible for the cost of repair, correction or coverage, if

the l contracted tools, gauges, fixtures, machinery and equipment fails to achieve the contracts

specified requirements.

36.7 It shall be the Supplier’s responsibility to incorporate error-proofing into all contracted

tools, gauges, fixtures and equipment to prevent the production of defective parts, assemblies

or the service intended. Error-proofing must not interfere with ease of loading or unloading of

the product.

36.8 The Supplier will be responsible for submitting a timeline and progress reports weekly to

the appropriate Minth Tooling Engineer and Buyer. If the tooling is being built outside of the

continental USA or at a distance greater the 500 miles from Minth North America, Farmington

Hills Michigan the supplier is required to provide digital pictures with each weekly report.

36.9 It shall be the Supplier’s responsibility to have CAD data for the tooling updated and

provided to Minth Americas prior to final Minth acceptance and payment.

36.10 One hard copy and one electronic copy of the Operating and Maintenance Manuals shall

contain the following:

Bill of Materials (Including Part Number index and schematic)

Sequence of Operations.

All contracted tools, gauges, fixtures and equipment designs including separate detail

drawings of components.

List of recommended spare parts/details.

36.11 Acceptance of contracted tools, gauges, fixtures and equipment will consist of:

A completed layout report, marked part print and six (6) sample parts are to be submitted

to Minth North America for PPAP approval.

36.12 When sample parts are approved, the Supplier will be notified at that time for the balance

of the parts required, as indicated by this purchase order. The appropriate Minth North

America personnel will be in the vendor's plant to observe the tool run at this time.

Capability will be measured by the following: 30 piece random sampling from a 300

PPAP piece lot run. 30 piece shall achieve a 1.67 CPK on all critical characteristics. All of

contracted requirement and specification shall be satisfied; This includes however is not

limited to; Tagging, run @ rate attainment, Dry Cycle – Slow then ramp-up to full


speed—No Part Present, Verify Rate (Cycle Time, Evaluate for appearance criteria (Clamp

Marks, Excessive Burrs, Dings, scratches, etc.) and all required contract compliance items.

36.13 If a part is rejected at any point this initial sample procedure, the tool must be corrected

and new samples run. Design features found not in accordance with these specifications will

be promptly corrected. The cost of disassembly correction and reassembly will be the

responsibility of the tool supplier.

36.14 MNA will arrange to have the plant personnel available for tool buy off. During the tool buy

off, the tooling checklist must be completed in full and signed by the appropriate personnel.

The final buy off will be at the assigned Minth North America plant.

36.15 The tool supplier shall be present at MNA receiving plant for the final buy off and assist

with any tool modifications needed during the first set-up and trial run off.

36.16 Payment and Purchase Terms.

36.17 The payment terms are detail in the Purchase Order Contract. If no terms are

provided then Minth Americas will pay 100% of the contract amount due Net 60 days

after Supplier has submitted the following:

36.17.1 Supplier Invoice that reference Minth Americas Purchase Order Number.

36.17.2 Proof of successful PPAP, Run @ Rate or agreed on Contracted condition(s) .

36.17.3 Minth Engineering and Buyer signed acceptance document.

36.17.4 Copy of the Original Minth Americas Purchase Order.

36.17.5 Proof of Delivery – Signed Shipper or Bill of Lading.

36.18 Progressive payment agreement - additional requirements.

36.18.1 Supplier Invoice that reference Minth Americas Purchase Order Number.

36.18.2 Payment Schedule Summary.

36.18.3 Proof of compliance to contracts timing and deliverables.

36.19 Only the Minth Americas Purchasing Department can modify, alter or accept a

deviation to the contracted terms, requirements or deliverables of an active Purchase

Order or agreement. All Purchase Order Contract modifications must be in writing and

issued by Minth Americas Purchasing Department.

North American Injection Mold Tooling Standards and ......Mold design. 3D solid. Mold build. Mold...

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