Poor release from the mould: What It Tells You About the Tool – Thick Gauge Work

poor release from the mould is one of the faults that shows up during sampling on any new thick gauge tool. It is visible on the part, but the cause is usually in the mould, the heating cycle or the material, and it is far cheaper to deal with at design stage than after the tool is cut.

What it affects

The main effects are on wall thickness, cycle time and how much hand work the part needs after forming. On a thick gauge part these three decide the piece price, so the decision taken here shows up in every release afterwards.

Typical values

How it is controlled

1. The part cools on a jig so the shape is held while the material stabilises.
2. Sheet is dried when the material needs it, then heated to forming temperature on the machine.
3. Tooling is cut: aluminium for production volumes, composite or printed moulds for samples and first articles.
4. Trimming is done on 5-axis routers or with a dedicated trim fixture to meet the drawing.
5. Drawings are reviewed and a manufacturability report is issued with wall thickness, draft and radii marked up.

Common mistakes

• plan the trim line on a flat face so the router can hold tolerance
• add ribs or returns instead of increasing sheet thickness to save weight and cycle time
• use corner radii of at least three times the sheet thickness to avoid thinning
• avoid sharp steps in the mould, which show as chill marks on the finished surface

How to specify it on the drawing

Put the decision on the drawing rather than in an email: state the material and grade, the gauge, the finish, the surfaces that must not carry marks, and the tolerance that applies to the trimmed edges. Where the part has to mate with another component, mark the datum faces so the trim fixture and the inspection report use the same reference. A drawing that states these points removes most of the questions that otherwise surface during sampling.

Checklist before tooling is cut

• Material and grade fixed, including flame retardancy, UV or food contact requirements
• Gauge selected from the load case, not from habit
• Draft angle and corner radii checked against the sheet thickness
• Trim line placed on a face the router can reach
• Finish and colour standard agreed, with a reference if the colour is critical
• Inspection points agreed and noted for the dimensional report

Related terms

• Production tooling
• Gloss measurement
• Twin sheet forming
• Threaded inserts
• Moisture in sheet
• Dimensional report

Frequently asked questions

Does this change the tooling cost?

Yes. Decisions taken at drawing stage move the tooling cost more than any later change, which is why the manufacturability review is done before the tool is cut.

What information do you need to advise on it?

A 3D file, the material if it is fixed, the annual quantity and the finish. With those the answer comes back with a recommended route and a quotation.