Challenge
Premetec undertook the challenge of designing and manufacturing a custom 2K-injection mold for a hand tool that demanded the highest precision. This project presented several complexities, including the need for precision part manufacturing with hard-to-work materials, quenching and tempering, intricate grinding, 3D-CNC machining, and advanced EDM (Electro-Discharge Machining) processes, including electrode manufacturing from copper/graphite and EDM wire cutting. The challenge was to meet these requirements while ensuring the final assembly produced flawless hand tools.
Insight
Design excellence: Our journey began with a meticulous design phase. Premetec’s design team employed state-of-the-art CAD software to create a precise blueprint that accounted for every intricate detail required by the hand tool.
Material expertise: Given the complexities involved, material selection was critical. We chose hard-to-manufacture materials that could withstand the rigorous demands of the hand tool industry.
Precision machining: Precision was paramount throughout the manufacturing process. Advanced 3D-CNC machining techniques were employed to create intricate features and geometries, ensuring the utmost accuracy in the mold’s components.
Quenching and tempering: To enhance the durability of the mold, quenching and tempering processes were applied. This step strengthened the mold, ensuring it could withstand repeated injections and provide a long service life.
EDM mastery: The heart of the project lay in the EDM processes. We utilized electro-discharge machining to create intricate shapes and details. Electrodes, crafted from both copper and graphite, were used for EDM, and meticulous wire cutting technique ensured precise results..
Assembly skills: The final assembly phase required the utmost care and precision. Each component was meticulously fitted together, ensuring that the mold functioned flawlessly and produced high-quality hand tools.
Results
Premetec’s unwavering commitment to precision and excellence yielded remarkable results:
High-precision mold: The custom 2K-injection mold delivered the exacting precision required for the hand tool, meeting all specifications and tolerances.
Exceptional durability: Through quenching, tempering, and precision manufacturing, the mold demonstrated exceptional durability, capable of withstanding the rigors of high-volume production.
Flawless hand tools: The final assembly phase ensured that the mold consistently produced flawless hand tools that met the highest industry standards.
Client satisfaction: Our client received a custom 2K-injection mold that not only met their exacting requirements but also surpassed their expectations. This success strengthened the partnership between Premetec and the client, reaffirming our commitment to excellence in industrial manufacturing.
In conclusion, this case study exemplifies our ability to tackle complex projects involving hard-to-manufacture materials, advanced EDM techniques, and intricate design requirements reaffirms our position as a leader in the industry, redefining what’s possible in precision engineering.