Engineering

At Liberty Molds, we transform your ideas into reality. Our experienced engineering team designs for manufacturability and optimal production. The engineers at Liberty Molds average 20+ years of experience in designing high-precision plastic injection molds for the most challenging parts.

Every successful project starts with a solid design. So right from the get-go, we engineer with an emphasis on functionality and efficiency. The robust design means not only longer-lasting tools but also time savings in production and fewer modifications. Our mold designers work closely with customer engineering departments to provide a smooth transition from design to the final product.

Computer-Aided Design (CAD)

At Liberty Molds, our experienced engineering team utilizes the most current CAD technology. We take into consideration all critical aspects of the mold design: Gating, venting, cooling, ejection, part transfer, manufacturability, and materials selection. It’s a challenging task, requiring a vast store of knowledge and expertise, as well as strict attention to every detail.

It also requires the most powerful software systems available. Liberty engineers utilize Cimatron, KeyCreator, and Esprit CAD software in their injection mold designs. This suite of advanced software creates solutions for conceptual designs, mold design, 3D solid modeling, and revision control, as well as tool drawings and documentation.

Computer-Aided Engineering (CAE)

Once the injection mold has been designed, it must be simulated to ensure proper performance. Simulation is where CAE comes in. We use Moldex 3D software to simulate the molding process and to predict pressure loss and fill scenarios. CAE works together with our CAD software to integrate the mold design with the part design and the molding activity. Fill analysis, thermal optimization, and warpage calculations are all simulated to ensure a superior mold design. 

Pressure, temperature, applied forces, and component interactions are entered into the CAE software, to simulate the actual mold performance.

Analyses include:

• Thermal and fluid flow analysis
• Stress analysis
• Nonconformity verification
• Multibody dynamics
• Manufacturing process analysis
• Optimization of process documentation

We make sure our molds will work correctly -- before we start cutting steel.

Computer-Aided Manufacturing (CAM)

Many of our molds are destined for demanding applications where consistent quality is essential. RJG in-mold sensors are a common feature integrated in the initial concept and design.

Even the most elegantly designed part is worthless if it can’t be efficiently manufactured. CAM software helps create, verify, and optimize the manufacturing process.

The engineers at Liberty Molds use Cimatron and Esprit CAM software to employ various machining strategies, such as milling, grinding, wire EDM, and sinker EDM.

This CAM software leverages the skills of our expert machinists, providing exceptional productivity while also minimizing expenses.

The result? More precise, tighter tolerances, and less part variance.

Electrical Discharge Machining (EDM)

EDM has completely revolutionized mold making. It allows us to create intricate designs that would otherwise be very difficult to produce with conventional tools. It also lets us machine extremely hard material and complex geometries with very high precision.

Wire EDM

In wire EDM, a thin brass wire is fed from a spool through the mold or insert. Material is removed through a series of rapid electrical discharges between the wire and the mold. Wire EDM is often used to cut plates as thick as 16.5" (420mm) and to produce tools, dies, and punches from hard metals. Because the upper guide on the wire EDM can move independently, tapered and transitioning shapes can also be created. It can be programmed to cut highly intricate shapes.

Sinker EDM

Details like recessed electrical and water fittings are engineered into our molds to help prevent damage when handling.With sinker EDM, a (usually carbon) electrode is placed in a dielectric fluid, along with the mold. An electrical current is then rapidly passed between the electrode and the mold, discharging a small amount of material from both the mold and the electrode. The strength and duration of the current can be adjusted to remove more or less material from the mold. Micro setting sinker EDM allows for precise control of the mold geometry so that complex three-dimensional shapes can be formed.

Trust the Liberty Engineering Team

But state-of-the-art software is only a part of the solution. To create high-precision injection molds, you need highly skilled and experienced professionals: designers, machine specialists, and mold makers. The Liberty team has what it takes to take your project from concept to production.

At Liberty Molds, we design an exceptional high-precision plastic injection tool – one that performs beyond expectations. When ultra-high precision is a requirement, you can trust us to overcome even the most challenging conditions.