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No. KDL is strictly a custom rubber molder producing molded parts to the customers furnished blueprints and specifications. All the tooling in our possession belongs to our customers and we cannot manufacture products for any customer out of another customers tooling.
Yes. Our minimum order varies based upon mold, process and operations being performed, therefore, each item is reviewed individually.
Most injection molds are machined from pre-hardened “tool steel” or Stainless Steel. Depending upon part size and configuration, the cavity area may be Tool Steel inserted into a mold base. Transfer and Compression molds can be pre-hardened but are sometimes made at a lower cost from E-45 or J-45 steel, depending upon anticipated production volume. Prototype molds are normally E-45 or J-45 Steel.
That is difficult to answer because each part is quoted individually and based on a customer furnished blueprint and specifications. No two parts are alike in weight, size, shape, function, complexity of design, material, etc. All parts require either the customer to furnish an existing mold to KDL or to have us manufacture a new mold. We can produce single cavity molds for prototyping or small run production and/or multi-cavity production molds. We will normally quote a wide variety of mold sizes.
LIM™ stands for “Liquid Injection Molding”. It utilizes L.S.R. or Liquid Silicone Rubber to produce the part. This is a relatively new process of injecting Silicone developed over the last 20 years. It uses equipment similar to plastic injection presses with the exception that the injection barrel is cooled and the platen or mold is heated to accomplish the “cure” of the polymer. There are several advantages to LIM™. In large quantities, the economies of scale are such that injection molding yields a much lower part price using fewer cavities. The process is relatively flash-free and clean making it ideal for many Medical, Food Grade, electronic and aerospace applications.
We have years of experience in recommending a particular polymer or type of rubber to customers. It is always based upon their specific application. Let us know the environment, including temperature, media exposure and other applicable characteristics required. We will be happy to make our best recommendation of a material from one of hundreds of formulas or develop a specific formulation for your particular application.
Lead times for parts vary upon the size of the order, availability of raw materials, and production scheduling. Normally, we are able to produce a product within 4 to 5 weeks and can sometimes produce partials much sooner to get customers out of scheduling conflicts. Again, this is based on our production scheduling. When new molds are made, the time to produce the mold and First Article Samples varies from a minimum of 3 to 5 weeks for a simple prototype mold up to 10 to 12 weeks for high cavitation hardened steel complex production molds. Typically, 6 to 8 weeks covers most mold order lead times and production can be scheduled to commence as soon as the customer has approved the First Article Samples.
All of the molds used by KDL to produce parts for specific customers are owned by those customers. If you do not already have an existing mold, we will work with you in creating a mold type for your particular application.
Yes. We mold these materials on a daily basis and specialize in them. We have a Cleanroom for high cleanliness sensitive products and mold U.S.P. Class VI Medical and Food Grade materials.
An Elastomer is a material that has the property of being elastic with resilience or memory sufficient to return to its initial shape after major or minor distortion within a reasonably short period of time. This property makes rubber materials excellent for sealing applications where its flexibility is highly important.
Native Solidworks, IGES file and a dimensional 2d drawing will get you the fastest quote possible.