Abstract: A method and apparatus are provided for total profile machining of a part, such as from a block of thermoplastic polymer. A first side of the part is machined together with an encircling recess. A registration/potting fixture is placed into the encircling recess. The registration/potting fixture is used to evacuate air from the machined side of the part and to pressure pack degassed fluid potting compound against the machined side of the part. The registration/potting fixture is cooled such as with a coolant to solidify the potting material. Then the registration/potting fixture is used to fixture the block in a new orientation for CNC machining another side of the part. Upon removal of the potting material from the part, the total profile machined part is freed for shipment to the customer.

Abstract: Any issues associated with manufacture of a part are identified and highlighted on a part model. A software method and system then uses motion of the part model for communicating the manufacturability issues to the customer. The motion can include a repositioning of a part rendering to a preferred orientation position, a fly-around so the customer can appreciate the next zoom location, and then a zooming in on the issue desired to be shown. Alternatively or in conjunction with the zooming and fly-around motion, the orientation of the part rendering showing the manufacturability issues can be three-dimensionally manipulated such as with a click-drag-drop command of the customer's computer mouse. By adding a moveable aspect to the communication, customers can much better understand which changes are recommended or required of the part.

Abstract: A software method allows a user to manipulate a three-dimensional object, particularly a custom designed part to be injection molded, on a computer screen with a mouse. The object or part is manipulatable about a center of rotation. The center of rotation is established on a face of the part, perhaps with a snapping feature to position the center of rotation on an edge of the part. A click-drag-drop rotation of the part is achieved based upon a spherical coordinate map of rotation, allowing the user to repositioning the object rendering. The spherical coordinate map of rotation repositions itself relative to the object based upon a pan command changing the view of the object. The preferred spherical coordinate map of rotation is an orientation globe which appears as an overlay during the click-drag-drop command.

Abstract: Any issues associated with manufacture of a part are identified and highlighted on a part model. A software method and system then uses motion of the part model for communicating the manufacturability issues to the customer. The motion can include a repositioning of a part rendering to a preferred orientation position, a fly-around so the customer can appreciate the next zoom location, and then a zooming in on the issue desired to be shown. Alternatively or in conjunction with the zooming and fly-around motion, the orientation of the part rendering showing the manufacturability issues can be three-dimensionally manipulated such as with a click-drag-drop command of the customer's computer mouse. By adding a moveable aspect to the communication, customers can much better understand which changes are recommended or required of the part.

Abstract: A customer sends a CAD file for the part to be manufactured to the system. The system assesses the CAD file to determine various pieces of manufacturing information. One or more acceptability criteria are applied to the part, such as whether the part can be machined in two opposing orientations in a 3 axis CNC machine. If not, the system sends a file to the customer graphically indicating which portions of the part need modification to be manufacturable. The system provides the customer with a quotation form, that allows the customer to select several parameters, such as number of cavities or parts per workpiece block, surface finish and material, which are independent of the shape of the part. The quotation module then provides the customer with the cost to manufacture the mold or a number of parts, which may include both molded parts and total profiled machined parts. Budget-driven quotation is possible, wherein proposed modifications in the molding process are controlled by the budget of the customer.

Abstract: A clamp is used to secure a heating element to an outside face of a mold. The clamp includes a frame portion which holds a commercially available cartridge heater. The frame portion is sized to mate with the cartridge heater for efficient conduction heating from the cartridge heater. The clamp attaches to the mold via recesses that can be machined into the mold on a three-axis mill, such as cylindrical opening machined in a direction parallel to and slightly intersecting the side face on which attachment occurs. The clamp includes a biasing mechanism for pressing the clamp into heat conducting contact with the outside face of the mold block to which it is attached, for efficient transfer of heat between the cartridge heater and the mold. The preferred biasing mechanism is through a screw lengthening/shortening mechanism, with the clamp attached on two side faces around a corner of the mold block. The biasing force is enhanced by a fulcrum ledge.

Abstract: A customer sends CAD files for two or more parts to be molded in a family to the system. The system provides the customer with a quotation form that allows the customer to select several family-level parameters which are independent of the shape of the part, such as material and delivery date. The quotation also allows the customer to select several part-level parameters which are independent off the shape of the part, such as quantity of each part and surface finish. The system assesses the CAD files to determine savings which can be achieved by molding the parts as a family, with multiple parts in the same mold block. If possible, the system machines cavities for the multiple parts into a single mold block, passing on reductions in cost to the customer both in the quote and in the final product delivery.

Abstract: A customer sends CAD files for two or more parts to be molded in a family to the system. The system provides the customer with a quotation form that allows the customer to select several family-level parameters which are independent of the shape of the part, such as material and delivery date. The quotation also allows the customer to select several part-level parameters which are independent off the shape of the part, such as quantity of each part and surface finish. The system assesses the CAD files to determine savings which can be achieved by molding the parts as a family, with multiple parts in the same mold block. If possible, the system machines cavities for the multiple parts into a single mold block, passing on reductions in cost to the customer both in the quote and in the final product delivery.

Abstract: A first customer provides a CAD file defining the surface profile for a part to be molded to the system, and a second customer does the same for a second part. The system determines whether the materials match and the run dates overlap, thereby qualifying the parts for use in a multi-customer mold block. The system assesses the part surface profile (which could have any of a virtually infinite number of shapes) of the parts submitted and lays out the parts from multiple customers on one or more multi-customer mold blocks. Savings are generated, such as by reducing redundancies in press clean-up, in set-up, in tooling, and in surface finishing. Due to these savings, the system provides a quotation of the part to at least one of the customers which differs from the quotation that would be provided if each part was run independent of parts of other customers.

Abstract: A computer program analyzes a CAD file provided by a customer of a custom part to be injection molded. Feedback from the analysis is provided to the customer through a rendering of the part. Rather than merely communicating using color as applied to the rendering file and separate text, the invention applies one or more symbols as “decals” to the rendering of the part provided to the customer. In one preferred embodiment, the symbols are chevrons or arrows which indicate the direction of additional draft needed on particular faces for the part to be sufficiently manufacturable. The symbols are sized appropriately for the size of the face to which they are applied, and are oriented to match the orientation of the face. The symbols may also indicate other information, such as the magnitude of draft needed, magnitude of thickness required, the surface finish to be applied at that location, or time or location based properties of the injection molding process.

Abstract: A customer sends a CAD file for the part to be molded to the system. The system assesses the CAD file to determine various pieces of mold manufacturing information. One or more acceptability criteria are applied to the part, such as whether the part can be manufactured in a two-piece, straight-pull mold, and whether the mold can by CNC machined out of aluminum. If not, the system sends a file to the customer graphically indicating which portions of the part need modification to be manufacturable. The system provides the customer with a quotation form, that allows the customer to select several parameters, such as number of cavities, surface finish and material, which are independent of the shape of the part. The quotation module then provides the customer with the cost to manufacture the mold or a number of parts. Budget-driven quotation is possible, wherein proposed modifications in the molding process are controlled by the budget of the customer.

Abstract: Automated, custom mold manufacture for a part begins by creating and storing a collection of information of standard tool geometries and surface profiles machinable by each of the standard tool geometries. A customer sends a CAD file for the part to be molded to the system. The system assesses the CAD file to determine various pieces of mold manufacturing information. One or more acceptability criteria are applied to the part, such as whether the part can be manufactured in a two-piece, straight-pull mold, and whether the mold can by CNC machined out of aluminum. If not, the system sends a file to the customer graphically indicating which portions of the part need modification to be manufacturable. The system provides the customer with a quotation form, that allows the customer to select several parameters, such as number of cavities, surface finish and material, which an independent of the shape of the part.

Abstract: Automated, custom mold manufacture for a part begins by creating and storing a collection of information of standard tool geometries and surface profiles machinable by each of the standard tool geometries. A customer sends a CAD file for the part to be molded to the system. The system assesses the CAD file to determine various pieces of mold manufacturing information. One or more acceptability criteria are applied to the part, such as whether the part can be manufactured in a two-piece, straight-pull mold, and whether the mold can by CNC machined out of aluminum. If not, the system sends a file to the customer graphically indicating which portions of the part need modification to be manufacturable. The system provides the customer with a quotation form, that allows the customer to select several parameters, such as number of cavities, surface finish and material, which an independent of the shape of the part.

Abstract: Automated, custom mold manufacture for a part begins by creating and storing a collection of information of standard tool geometries and surface profiles machinable by each of the standard tool geometries. A customer sends a CAD file for the part to be molded to the system. The system assesses the CAD file to determine various pieces of mold manufacturing information. One or more acceptability criteria are applied to the part, such as whether the part can be manufactured in a two-piece, straight-pull mold, and whether the mold can by CNC machined out of aluminum. If not, the system sends a file to the customer graphically indicating which portions of the part need modification to be manufacturable. With any such modifications, the system provides the customer with a quotation of the cost to manufacture the mold or a number of parts. The quotation is based upon mold manufacturing time as automatically assessed from the part drawings.

Abstract: Automated, custom mold manufacture for a part begins by creating and storing a collection of information of standard tool geometries and surface profiles machinable by each of the standard tool geometries. A customer sends a CAD file for the part to be molded to the system. The system assesses the CAD file to determine various pieces of mold manufacturing information. One or more acceptability criteria are applied to the part, such as whether the part can be manufactured in a two-piece, straight-pull mold, and whether the mold can by CNC machined out of aluminum. If not, the system sends a file to the customer graphically indicating which portions of the part need modification to be manufacturable. The system provides the customer with a quotation form, that allows the customer to select several parameters, such as number of cavities, surface finish and material, which an independent of the shape of the part.