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HI-TECH REFERENCE & GUIDELINES ON MOLD & INSERTS
 
MOLD CLASSIFICATIONS
 

CLASS NUMBER NO of SHOTS
(Approx. & for comparison only)
NORMAL TOOL LIFE PRODUCTION
Class 101 More than 1M shots +5 Years Long Term; Extremely high production
Class 102 At least 1M shots +3 Years Medium to high volume production
Class 103 At least 500K shots 3 Years Medium production
Class 104 At least 100K shots 1-2 Years Small volume production
Class 105 Less than 500 shots Prototype Inexpensive and limited quantity
Classifications of Inserts

Descriptions:
 
Class 101: This is the highest-priced mold and is made with only the highest quality materials.

  1. Detailed mold design required. Condition upon mold approval.
  2. Mold base to be minimum hardness of 280 BHN (DME#2 Steel/4140 Steel).
  3. Molding surfaces (cavities and cores) must be hardened to a minimum range of 48~52 HRC. All other details, such as slides, heel blocks, wedge blocks, etc. should also be made of hardened tool steels.
  4. Ejection should be guided.
  5. Slides must have wear plates.
  6. Temperature control provisions to be in cavities, cores and slides wherever possible.
  7. 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.
  8. Parting line locks are required on all molds.
  9. Insert to use must be equivalent to EU or NA grade and quality
  10. Mold components to be compatible with Hasco or DME brands.
  11. All cavities, cores and inserts to be stamped with required and/or special identification.
 
Class 102:Medium to high production mold; good for abrasive materials and/or parts requiring close tolerances. This is a high quality, fairly high-priced mold.

  1. Detailed mold design required. Condition upon mold approval.
  2. Mold base to be minimum hardness of 280 BHN (DME#2 Steel/4140 Steel).
  3. Molding surfaces should be hardened to a 48~52HRC. All other functional details should be made and heat treated.
  4. Temperature control provisions to be directly in the cavities, cores, and slides wherever possible.
  5. Parting line locks are recommended for all molds.
  6. The following items may or may not be required depending on the ultimate production quantities anticipated. It is recommended that those items desired to be made a firm requirement for quoting purposes:
    1. Guided Ejection
    2. Slide Wear Plates
    3. Corrosive Resistant Temperature Control Channels
    4. Plated Cavities
  7. Mold components to be compatible with Hasco or DME brands.
  8. All cavities, cores and inserts to be stamped with required and/or special identification.
 
Class 103: Medium production mold. This is a very popular mold for low to medium
production needs. Most common price range.

  1. Detailed mold design recommended. Condition upon mold approval.
  2. Mold base must be minimum hardness of 165 BHN.
  3. Cavity and cores must be 280 BHN or higher.
  4. Mold components to be compatible with Hasco or DME brands.
  5. All cavities, cores and inserts to be stamped with required and/or special identification.
 
Class 104:Used only for limited production preferably with nonabrasive materials. Low to moderate price range.

  1. Mold design recommended and appropriate dimensions required.
  2. Mold base can be of mild steel or aluminum.
  3. Cavities can be of aluminum, mild steel or any other agreed upon metal.
  4. Mold components to be compatible with Hasco or DME brands.
  5. All cavities, cores and inserts to be stamped with required and/or special identification.
 
Class 105:This mold will be constructed in the least expensive manner possible to product a very limited quantity of prototype parts.
May be constructed from cast materials like aluminum alloy or epoxy or any other material offering with sufficient strength to produce minimum prototype pieces.
 
 
INSERTS:

CLASS I UNIT INSERT
Cycles: Approximately 500,000 shots
Description: Top quality materials for medium to high production requirements.

  1. Detailed mold design required.
  2. Insert retainer to be uniform hardness of at least 280 BHN.
  3. All molding and/or functional details are to be made of tool steel hardened to at least 48 HRC
  4. Slides must have wear plates.
  5. Temperature control provisions to be in cavities, cores and slides wherever possible.
  6. 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.
  7. Parting line locks are required to be on all molds.
  8. Insert retainers must have leader pins and bushings or some similar guidance system.
 
CLASS II UNIT INSERT
Cycles: Under 100,000 shots
Description: Similar to Class 104 Mold. Most commonly used insert. Low to medium production.

  1. Detailed mold design recommended.
  2. Insert retainer to be uniform hardness of at least 165 BHN.
  3. Cavities and cores must be 280 BHN or higher.
  4. Water channels to be included.
  5. All other extras are optional.
 
CLASS III UNIT INSERT
Cycles: Less than 500 shots
Description: Similar to Class 105 Mold. Least expensive insert for very limited quantities. Insert built with the lease expensive materials.
Can be constructed from aluminum, cast metal, cast epoxy or any material with sufficient strength to produce minimum prototype parts.

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