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My dad was (amongst many other things) a toolmaker who made plastic injection molds. These things can be hideously complicated, especially if the designer doesn
by versteegen 3y ago
My dad was (amongst many other things) a toolmaker who made plastic injection molds. These things can be hideously complicated, especially if the designer doesn't understand how it will actually be built, and as a result he once spent a year on one. In his days everything was manual, no CNC, no 3D models, no simulations, and probably no contact with the designer to make improvements.
He had to cut milling bits with custom profiles to cut custom tools such as a series of graphite and copper spark eroder forms to cut just some of the corners and shapes in the (paper) technical drawings, then repeat for the next ill-advised bevel or interior sharp angle or even lettering which is too close together to get a milling bit inbetween two letters. Figuring that out was his responsibility alone. Instead of computer control, he'd have to do something like first create a scale model of part of the tool out of a block of plastic, then use a pantograph (a mechanical linkage allowing you to trace a shape with a pen and have the movement magnified/minified) to copy the shapes on a milling machine -- even shapes that seem simple. And then maybe throw away (actually, take home as a souvenir) a month or two's work if you cut slightly too deep -- these were high precision parts. Not because the plastic had to be so precise, but because the completed dies are made out of many steel parts that have to fit tightly together and slide past each other, as you can see in the article.
Considering the ~two months quoted in the article for this mold, I'd think a lot of that complexity is still essential despite modern computerized machining. I'm sure a great deal of ingenuity and many steps are still needed.
- versteegen 3y agoAddendum: I asked my dad and he said what I overlooked is that it takes far less thought and skill to make a mold or other tool today not just because of CNC (to cut paths you can't by manually turning knobs), but because of the algorithms that plan out how to make it.