Aluminum Mold Making

Computer Directed

• Computer-directed machinery produces molds and tools with precision to within 1/1000th of an inch, based on a virtual prototype, according to Cascadequalitymolding.com. Computer-directed results surpass the results of machinists on lathes.

  Mold makers use computer software that enables them to scrutinize the product or part three dimensionally, before proceeding to create the aluminum mold to manufacture that product or part. The company works with state-of-the-art mold designers and manufacturers, and subcontracts other processes.

High Spindle Speed

• According to Datron Dynamics, high spindle speed is key to producing a superior surface finish in aluminum molding. Manufacturers like Datron specialize in milling aluminum. The company offers German-engineered, turn-key aluminum mold milling as well as engraving systems with full-automation capability.

  Datron systems suit a worldwide market of applications, designed to encourage diversified manufacturing capabilities and greater production efficiency in precision micro machining and industrial engraving, principally in small tools.

Permanent Mold Casting

• Permanent mold aluminum casting is the rapid heat transfer of molten aluminum into steel molds under gravity, centrifugal force or low pressure. According to manufacturers like Southland Machine and Mold, Inc., this precision process produces finer grain structures in the castings than through sand casting. It also results in lighter castings with thinner walls.

  Permanent mold castings offer advantages over die castings. The latter often contain entrapped gas. Permanent mold castings are also a step up from sand castings, which can have shrinkage and gas porosity.

Molding for Hobbyists

• Aluminum bar stock is the material of choice for making machined molds. The starting point is a CAD drawing of the part or product to be made. This becomes the basis for a CAD drawing for the mold and additional features like air vents. The mold drawing provides the necessary information for the CAM program that guides a CNC machine to cut the metal using specific tools.

  Aluminum mold making requires considerable technical knowledge and skill. It is a challenging process for the hobbyist, who opts to take up the challenge rather than handing the CAD drawing to a machinist or mold maker to produce. There are bench-top CNC machines available that are hobbyist friendly.