Surlyn Perfume Cap Plastic Mold Manufacturing

Name: Surlyn Perfume Cap Mold Manufacturing Process: CNC Machining, Mirror EDM Machining, Mold Trial Mold cavities:1*8 surface finish: VDI 4-6 Mold Material: 2083 Part material: Surlyn Mold Lead time: 6 weeks

Customer Overview

Our customer is a perfume company based in the United States. They specialize in the research, development, production, and sales of perfumes. They have their own injection molding factory and were seeking a mold manufacturer who can offer high-quality perfume cap mold to meet their production needs. The customer initially approached several mold companies, obtaining quotations from over ten companies. After careful consideration, they ultimately chose to collaborate with Alpine Mold for the production of one set of precision perfume cap mold for export to the United States.

Perfume Cap Appliance

Surlyn Perfume Cap

Project Overview

The customer provided detailed 3D drawing of the perfume cap and and specify demands in details: resin, finish, demand quantity etc, we provided quotation in 48 hours. After our customer accepted our price and placed the order, Alpine Mold's team of experienced engineers and technicians carefully reviewed the 3D drawings. They meticulously analyzed the design specifications, dimensions, and intricacies of the perfume caps to ensure a precise replication in the mold manufacturing process.

Throughout the project, Alpine Mold maintained close communication and collaboration with this customer. Regular updates, discussions, and consultations were conducted to address any queries, modifications, or additional requirements from the customer's end. This close partnership allowed for a seamless exchange of information and ensured that the final perfume cap mold would align perfectly with the customer's expectations.

How We Made - Surlyn Perfume Cap Mold Process

1. Perfume Cap Mold Design

Considering the customer's column size of 420mm x 420mm for their injection molding machine, Alpine Mold designed the perfume cap molds to be as compact as possible to fit within these specifications. The following design considerations were implemented:

Gate Placement: The gate, which is the point of entry for the molten material, was strategically positioned from the sprue to the center of the cap's top. This ensured proper material flow and minimized the risk of cosmetic defects on the cap's visible surfaces.

Inverted design: The interior of the mold featured an inverted design, while the exterior had a straight profile. This design allowed for easy ejection of the molded caps and facilitated efficient production.

Half-Cavity Rotation: To optimize the molding process, the mold was designed with a half-cavity rotation or "Hafer line." The mold halves were angled at 45 degrees, allowing for smooth ejection of the caps and minimizing the risk of damage or distortion during demolding.

2. Perfume Cap Mold Manufacturing

Material Preparation: We selected high-quality 2083 mold steel material for its durability and suitability for mold production. Our team carefully prepared the mold steel, ensuring it was clean and free from any impurities or defects.

Rough Machining: We loaded the prepared mold steel into our CNC machine. Using computer-aided instructions, we precisely carved and shaped the mold components according to the design specifications. Our rough machining process removed excess material and created the basic shape of the mold.

Heat Treatment: To enhance the hardness and durability of the mold, we performed a heat treatment process. We carefully heated the mold components to a specific temperature and then cooled them at a controlled rate. This heat treatment ensured that our molds achieved the desired mechanical properties, such as hardness and toughness.

Precision Machining: After the heat treatment, our expert machinists performed precision machining using our CNC machines. This step refined the dimensions, achieved tight tolerances, and created intricate details necessary for the final mold assembly.

EDM (Electrical Discharge Machining): We utilized Charmilles EDM machines to perform VDI 4-6 surface treatment on our mold. Through EDM, we used electrical discharges to shape and refine the mold surface. This process provided a smooth finish, eliminating any roughness or imperfections on the mold cavities and cores. EDM also allowed us to create fine details and complex geometries that are challenging to achieve through traditional machining methods.

Charmilles EDM machines

VDI surface treatment

Polishing and Finishing: Our skilled technicians carried out polishing and finishing processes to further enhance the surface quality of our mold. We utilized specialized tools and techniques to ensure a smooth and flawless surface finish, reducing the risk of defects on the molded perfume caps.

Assembly and Testing: Our experienced team carefully assembled the individual mold components, ensuring proper alignment and functionality. The assembled mold then underwent rigorous testing and trial runs to verify its performance, functionality, and compatibility with the customer's injection molding machine.

Sample Confirmation: After mold trial was finished, we provided samples of the molded perfume caps to the customer for their approval. These samples allowed the customer to assess the quality, aesthetics, and functionality of the molds and make any necessary adjustments or modifications if needed.

Package and Shipping: When the samples were approved, we took great care in packaging the molds to ensure their safe transportation. To provide optimal protection, we used a sturdy wooden box specifically designed for shipping purposes. The wooden box served as a robust barrier, shielding the surlyn perfume cap mold from any potential damage or contamination during transit.

Customer Satisfaction and Results

At Alpine Mold, we pride ourselves on delivering precision molds that meet and exceed customer expectations. For our US-based perfume company partner, the successful production of the Surlyn perfume cap mold is a testament to our commitment to quality, innovation, and customer collaboration. The seamless process—from initial consultation to final product delivery—demonstrates our dedication to ensuring optimal results, helping our client achieve flawless, high-quality perfume caps for their production lines.

Do you also need high-quality custom molds for Surlyn Perfume Cap ? Contact us today! We are focusing on offering precise mold manufacturing and injection molding services designed to meet your specific needs. Reach out for a detailed quotation and discover how Alpine Mold can support your next project!