The VEC System is Your Choice for Precision.
Floating Mold Technology
VEC Composite Technology developed a patented state-of-the-art closed-molded low-pressure injection molding we call The Floating Mold.
The Floating Mold tooling is based on the fundamental principle that fluids such as water are non-compressible in the pressure ranges used in closed molding. The benefits of the Floating Mold technology are:
- Reduced tooling cost
- Reduced cycle times
- Increased speed to market
- Increased molding flexibility and performance
- Precision in weight and dimension
The Floating Mold construction starts with a master model that is used to create the two molding surfaces (mold skins). One female mold skin (Side A) and one male (Side B) are produced to create the proper cavity size between them.
Special attachment flanges and all necessary closed-molding hardware, such as sprues and ejectors, are all molded into the mold skins. A set of universal vessels is created (Sides A and B): one for the female half of the mold and one for the male half. The universal vessels are outfitted with special attachment flanges. Each mold skin is attached to its own universal vessel with a custom flange that creates an airtight seal between the vessel and the skin.
Next, the two assembled mold halves are filled with water or any non-compressible fluid, and all air is purged from the interior of both vessels through a system developed by VEC Technology. Due to the non-compressibility of the fluid, the mold is now a rigid hydraulic system. Any forces exerted on the skin such as internal injection pressures are now transferred through the fluid to the exterior pressure vessel. The universal vessels are designed to handle the maximum potential pressure generated from the injection process.
At this point, the mold is ready to make parts. The two assembled mold halves are placed in a lifting frame, which will allow the tool to be opened and closed. Once the mold halves are closed, the injection process is started.
Since the mold is fluid filled, it has excellent thermal conductivity, which allows for improved temperature control of the mold surface. These features result in reduced cycle time and improved cosmetics.
The Universal Vessels incorporate an internal Smart System to monitor pressures and temperatures throughout the molding cycle. These response systems are designed to close the loop between the injection equipment and the Floating Mold. It allows injection profiles to be adjusted dynamically based on actual mold condition and parameters; therefore, optimizing the injection process. These features result in greater part-to-part constancy, reduced cycle time, and improved cosmetics.
VEC Composite Technology's Floating Mold system allow us to maximize efficiencies in tooling costs and tooling life based on the materials used to manufacture the mold skins. Mold skins can be manufactured using various materials including:
- Chopped fiberglass skins for prototypes and low annual volume
- Mats, fabrics, and roving reinforced for low-to-mid annual volume
- Cast aluminum for high annual volume
Then Floating Mold system dramatically reduces tooling costs due to minor part design changes, as the changes can be easily incorporated into the mold skins. Major part design changes can be accomplished through new skins. Additionally, attachment flanges and the Universal Vessels can be re-used.
Generally, tools for closed molding applications are either machined or cast out of very expensive aluminum metals, composites, or metal alloys. These types of tools are costly, have long lead times, and are difficult to modify and repair.
Applications using The Floating Mold technology include:
- hoods for earth moving and farming equipment
- golf cart hoods
- underground trenches and sumps
- structural and flotation foam structures
- institutional furniture
- boat hulls
- decks
- and other marine applications
