Rapid US-Based
Injection Molding

Summit Plastic & Tooling

Services

Part and Mold Design

CAD / CAM Software Platforms

Part designs can be received in a wide variety of 2D/3D formats (see below). Once geometry is received, Summit imports them into SolidWorks to design a 3D models of the necessary tooling (CAD) and utilizes MasterCam to generate all of the tool paths for machining.

Prototype Tooling

In our prototype tooling, our experts bring state-of-the-art technology together with traditional mold making techniques. We offer complete prototype part designs from concept to finished injection molded prototypes. Summit Tooling by Fathom offers a variety of techniques to accomplish this, dependent upon each customer needs, desires, and budgets.

The focus in today’s prototype world has been to create prototypes which mimic the production component, in the areas of precision, part weight, cycle times, and tooling costs. Our goal is to ensure that we meet and exceed our customers’ expectations with prototypes that are delivered quickly, accurately.

Our process begins with meeting and discussing the goals of the customer prototype component and deciding as to the type of prototype tooling that fits their needs. We offer low volume tooling – aluminum molds, hand molds, MUD molds, and Unit Molds. In some extreme cases, higher volumes are required for prototypes and we may suggest a Bridge tool, where we would completely build out (1) cavity within a multi-cavity production tool. This will allow the customer to test out the prototype component and make changes, if necessary. The balance of the cavities can then be created to the exact specifications of this original cavity. This is a major costs savings going from the prototype process to production.

 Production Tooling

We realize production cycle times are one of the most critical factors when considering piece part costs as it relates to the type of production tooling features. Production tools need to process, cool, and eject parts quickly. There are many factors to consider when trying to achieve optimum cycles and we offer many techniques, which we have learned, experimented with, and succeeded with, over our many years of experience and knowledge of doing prototype components. We offer small to medium size production tooling. Tooling capacity will vary dependent upon piece part size and we can accommodate cavitations ranging from 1 to 16 cavity. Mold base materials can also come in a variety depending on our customers’ needs, ranging from aluminum to stainless steel.

We do follow SPI Production Mold classifications standards. These are as follows:

INTRODUCTION

The following classifications are guidelines to be used in obtaining quotations and placing orders for uniform types of molds. It is our desire through these classifications to help eliminate confusion in the mold quote system and increase customer satisfaction. It is strongly recommended that mold drawings be obtained before construction is started on any injection mold. Even though parts may seem simple enough not to warrant a mold design, a drawing showing sizes and steel types will pay for itself in event of mold damage. These classifications are for mold specifications only and in no way guarantee workmanship. It is very important that purchasers deal with vendors whose workmanship standards and reliability are well proven. Mold life, because of variations in part design and mold conditions, cannot be guaranteed. This guide will attempt to give approximate cycles for each type of mold excluding wear caused by material abrasion, poor mold maintenance and improper molding technique. Maintenance is not the responsibility of the mold maker. Normal maintenance such as replacement of broken springs, broken ejector pins, worn rings, or the rework of nicks and scratches should be borne by the molder. Mold rework costs should be closely considered when deciding which classification of mold is required. This document does not constitute a warranty or guarantee by the Society of the Plastics Industry, Inc., or its members for the classifications or specifications set forth herein.

CLASSIFICATION OF INJECTION MOLDS UP TO 400 TONS

The following contains a brief synopsis of the various mold classifications and the detailed descriptions of each mold class. Again, it is our recommendation that a MOLD DATA SHEET (an example of which is in the back of the SPI manual) be included with each request for quotation.

GENERAL SPECIFICATIONS

1. Customer to approve mold design prior to start of construction.
2. All molds, with the exception of prototype, to have adequate channels for temperature control.
3. Wherever feasible, all details should be marked with steel type and Rockwell hardness approximately .005 deep.
4. Customer name, part number, and mold number should be steel stamped on mold.
5. All molds should have eyebolt holes on the top side. There should be one above and one below the parting line to facilitate mold removal, if required, in halves.

CLASS 101 MOLD

Cycles: One million or more

Description: Built for extremely high production. This is the highest priced mold and is made with only the highest quality materials.

• Mold base to be minimum hardness of 28 R/C.
• Molding surfaces (cavities and cores) must be hardened to a minimum of 48 R/C range. All other details, such as sub-inserts, slides, heel blocks, gibs, wedge blocks, lifters, etc. should also be of hardened tool steels.
• Ejection should be guided.
• Slides must have wear plates.
• Temperature control provisions to be in cavities, cores and slide cores wherever possible.
• Over the life of a mold, corrosion in the cooling channels decreases cooling efficiency thus degrading part quality and increasing cycle time. It is therefore recommended that plates or inserts containing cooling channels be of a corrosive resistant material or treated to prevent corrosion.
• Parting line locks are required on all molds.

CLASS 102 MOLD

Cycles: Not exceeding one million

Description: Medium to high production mold, good for abrasive materials and/or parts requiring close tolerances. This is a high quality, fairly high priced mold.

• Detailed mold design required.
• Mold base to be minimum hardness of 28 R/C.
• Molding surfaces should be hardened to a 48 R/C range. All other functional details should be made and heat treated.
• Temperature control provisions to be directly in the cavities, cores, and slide cores wherever possible.
• Parting line locks are recommended for all molds.

The following items may or may not be required depending on the ultimate production quantities anticipated. It is recommended that those items desired be made a firm requirement for quoting purposes:

1. Guided Ejection
2. Slide Wear Plates
3. Corrosive Resistant Temperature Control Channels
4. Plated Cavities

CLASS 103 MOLD

Cycles: Under 500,000

Description: Medium production mold. This is a very popular mold for low to medium production needs. Most common price range.

• Detailed mold design recommended.
• Mold base must be minimum hardness of 8 R/C.
• Cavity and cores must be 28 R/C or higher.
• All other extras are optional.

CLASS 104 MOLD

Cycles: Under 100,000

Description: Low production mold. Used only for limited production preferably with non-abrasive materials. Low to moderate price range.

• Mold design recommended.
• Mold base can be of mild steel or aluminum.
• Cavities can be of aluminum, mild steel or any other agreed upon metal.

CLASS 105 MOLD

Cycles: Not exceeding 500

Description: Prototype only. This mold will be constructed in the least expensive manner possible to produce a very limited quantity of prototype parts.

• May be constructed from cast metal or epoxy or any other material offering sufficient strength to produce minimum prototype pieces.

Production Molding

Summit Tooling by Fathom has a state-of-the-art molding facility utilizing 15 Injection Molding Presses ranging in size from 40 Ton to 350 tons. We have capability of processing multi-shot tooling, Bi-injected tooling, insert over molding, and most conventional molds.

We can accommodate many different types of colorant delivery systems from granular to liquid colorants. Other services we offer include Pad Printing, Hot Stamping, Ultrasonic Welding, Secondary Operations, and Light Assembly.

Location and Services

Summit Plastics & Tooling is located in McHenry, Illinois but services all the following local areas and more: Illinois – Chicago, Aurora, Naperville, Joliet, Rockford, Springfield, Elgin, Peoria, Champaign and Elk Grove; Indiana – Gary, South Bend, Fort Wayne and Indianapolis; Wisconsin – Madison, Milwaukee, Racine and Kenosha; Iowa – Davenport, Iowa City and Cedar Rapids. Additional areas can receive drop shipped parts or be served by other Fathom facilities that span the entire United States across the areas of additive, CNC machining, injection molding, sheet metal fabrication and over 25 different manufacturing processes.

About Summit Tooling

Our Mission

The mission of Summit Tooling is to fully satisfy the expectations of our customers by producing the highest quality products, on time, through dedication to excellence in everything we do, to provide customer satisfaction, and to continuously make improvements. The combination of the latest equipment, our experienced technical staff, and our sincere commitment to quality will ensure the highest level of quality parts with on time deliveries. As part of the Fathom Manufacturing Platform, Summit Tooling has access to a robust nationwide network of comprehensive additive and advanced manufacturing capabilities.

What We Do

Summit Tooling can help you take your project from concept to design, prototyping to production. Some of the markets we serve include Healthcare, Consumer Products, Electronics, Automotive, and Packaging, just to name a few.

We offer conventional injection molding, 2-shot technologies, thin wall high speed molding, and insert molding. We utilize a wide variety of auxiliary equipment to support this as well. We process thermoplastic material from commodity resins to engineering thermoplastics.

Short Run Molding

By taking advantage of our quick change tooling method whenever possible, Summit has become very efficient at making mold changes. By using special molding procedures, we optimize every aspect of short run work. From purchasing and drying small lots, to scheduling and shop floor flow, we ensure superior value to our short run customers.

Summit Tooling in the Media

• Competitive Mold Maker – In this article we discuss how the automation of mills and EDMS reshapes over Summit Tooling’s mold making.
• EDM Today, Spring 2012, Volume 21/ Issue 2 – In this article we demonstrate and explain how some of the latest CNC EDM technology, accompanied with precision hole popping, can improve capabilities and deliveries.

 

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Contact Us

Summit Tooling by Fathom

1207 Adams Drive
McHenry IL, 60051

Phone: 815-385-7500
Email: sales.mchenry@fathommfg.com
Fax: 815-385-7520