Injection Mould Toolmaking

Depending on when the project was quoted, we will review and update accordingly. All quotations and technical records are kept within our bespoke, project-based CRM database and are easy to find and edit.

As an ISO9001 registered company, we have an approved process for maintaining meticulous data records for part and tooling data. This is most important within the plastics industry as several versions of each variety are generated throughout the life of a project.

The ‘Design for manufacture’ DFM process will be carried out for every part that is to be moulded. Results of the DFM will be carried into the tool design process. We will also complete a moulding analysis (MFA) which will also be applied to the tool design process.

During this process we work with the client and our tooling partner to generate a 3D GA that will be an exact replica of the tooling that will be supplied.

By utilising the DFM and MFA processes into the design, we can assure the client that every measure has been taken to ensure that the final moulded product is what they want.

Our structured GA review process identifies every detail of the impressions that produce the part and the features that interface with the clients press. The review checklist works through physical dimensions, feed locations, ejection, hydraulic and electrical connections…to name a few.

Liondell will review the GA at least once before presenting it to the client for approval. In this way, we minimise the time that the client spends on review and approvals.

Once the GA is approved, our database will automatically produce a tool confirmation document. This outlines all of the key features of the tool, Press details, Shrinkage, Part Data levels (2D and 3D) and Approved GA revision.

This document will be held on the database and also physically filed as a PDF.

When a ‘steel order’ or approval for full manufacture is given the confirmation sheet is updated with the key milestone dates and sent to the tooling partner for the project.

In the week following the steel order, we will start to send photo progress and timing plan updates to the client. Our timing plans are kept in the cloud and shareable with clients. These plans are kept updated through to tool shipment.

Since early 2020, all tool trials are attended by the Liondell project manager based in Dongguan province. Prior to the pandemic, Liondell UK frequently visited Dongguan province. However, as travel restrictions and quarantine is still in place, we choose not to visit until normality resumes.

The following is a typical (3 trial) package. Occasionally it takes longer than 3 trials, but on average, 3 trials are sufficient to get approval.

Trial 1

• Trial Report – usually completed the same day, reports include:
  • Detailed photos of tooling and parts
  • Material usage
  • Process parameters
  • Press details
  • Video – 1 or 2 cycles
• Ship samples to Liondell
• Samples to Client
• ISIR Report(s) – within 2-3 days of trial
  • Liondell will review the ISIR report at least once before presenting it to the client for approval. In this way we minimise time that the client spends on review and approvals.
• Corrective action report(s)

Trial 2

• Trial Report
• Ship samples to Liondell
• Samples to Client
• ISIR Report(s)
• Corrective action reports(s)
• Grain Maps – if texture required

Texture added

Trial 3

• Trial Report
• Ship samples to Liondell
• Samples to Client
• ISIR Report(s)

Part approval

VTC (Virtual tool checking):

• The tool is physically checked to approved GA.
• All press interface connections are checked and verified
• Cooling circuits are pressure and flow tested and video taken on site by Liondell project manager

Once completed to our satisfaction the VTC report (PPT) and any videos are sent to the client for final approval.

• Latest 3D GA
• Steel Certificates
• PPT Manual in case of change inserts
• ISIR
• Process Parameters

• Sea or Air Freight through our approved logistics partners unless the client wants to use their own shippers.
• Tool received at client and ready to plug straight into the press.