Popper Mold-Tech was approached by a client to create a mold for a medical stool. The stool needed to be strong, lightweight, and ergonomic. As a trusted injection mould company, we started the injection molding process while preparing for any challenges that might arise.
Client’s Design and Needs
The client’s design included a comfortable, ergonomic seat and sturdy legs to support heavy loads. Our mold maker team analyzed the design and spotted potential issues in the leg structure. The thin legs could lead to uneven plastic flow during injection molding.
Material Selection Process
The stool needed to be strong and lightweight. Our mold maker experts recommended polypropylene. It is durable and easy to clean, making it ideal for medical environments.
During the injection molding process, we noticed a problem with the plastic flow in the legs. The material wasn’t reaching all parts of the mold evenly. To solve this, our injection mould company team adjusted the gate placement in the mold to allow for better flow.
Mold Adjustments and Testing
After fixing the flow problem, we tested the mold. However, another issue arose. The legs of the stool were slightly warped. This was due to uneven cooling in the mold.
Our mold maker team redesigned the cooling system. We added cooling channels directly to the leg areas. This ensured even cooling, and the warping problem was solved.
Final Production Stage
After these adjustments, we provided the client with sample stools. The client was satisfied with the strength, design, and weight of the stools. Our injection mould company then moved to full production. The final product met all of the client’s requirements.
Creating a medical stool mold required attention to detail and problem-solving. At Popper Mold-Tech, our expertise as a mold maker allowed us to overcome issues with material flow and cooling. Through careful adjustments, our injection molding process delivered a high-quality product that satisfied the client.