Precision Geometric Injection Moulding
This project demonstrates our capability in moulding geometrically precise parts with uniform wall thickness on all six faces. The ABS cube required dimensional tolerances of ±0.05mm on each face, perfect edge definition without sink marks, and a Class A surface finish suitable for painting or printing.
Achieving uniform shrinkage on a cube geometry is one of the more challenging tasks in injection moulding. Non-uniform cooling creates differential shrinkage that warps the part. Our mould design uses conformal cooling channels to ensure even temperature distribution across all cavity surfaces.
Material: High-Flow ABS
We selected Novodur P2MC (INEOS Styrolution), a high-flow ABS grade designed for thin-wall applications with excellent surface finish. The high melt flow index (25 g/10min) ensures complete cavity filling without excessive injection pressure that could cause internal stress and subsequent warpage.
Mould Engineering
The mould features conformal cooling channels produced by DMLS (Direct Metal Laser Sintering), reducing cooling time by 35% compared to conventional drilled channels. Gate location is optimised via Moldflow simulation to place the weld line on a non-visible edge.
The cavity surface is polished to SPI A1 (mirror finish) and chrome-plated for longevity. Expected mould life: 1,000,000+ cycles.
Process Optimisation
Scientific moulding methodology was applied: DOE (Design of Experiments) to optimise pack pressure, hold time, and cooling time. The result is a robust process window with Cpk >1.67 on all critical dimensions, ensuring consistent quality across production runs.
Quality Assurance
Each production run is validated with CMM (Coordinate Measuring Machine) inspection. Flatness, perpendicularity, and dimensional measurements are recorded for full traceability. ISO 9001:2015 certified production.
Applications
Precision cubes serve as display elements (retail, exhibition), educational tools (STEM learning), game pieces, calibration standards, modular construction systems, and architectural models. Custom sizes from 10mm to 100mm per side.
Frequently Asked Questions
What tolerances can you achieve on cubic parts?
Standard tolerance: ±0.05mm per face. High-precision option: ±0.02mm with additional process controls and 100% CMM inspection.
What colours and finishes are available?
Any RAL or Pantone colour in the base material. Surface options: high-gloss, matte, soft-touch, metallic effect. Post-moulding: painting, chrome plating, laser engraving.
Technical Specifications
Material: ABS Novodur P2MC | Tolerances: ±0.05mm | Surface: SPI A1 mirror polish | Mould: 4-cavity, conformal cooling | Cycle: 18s | Mould life: 1M+ cycles | Sizes: 10-100mm