The Bottom Line
Phygen applied their patented plasma-accelerated FortiPhySM coatings to core pins in an “impossible” mold and improved release properties significantly.

The Numbers
With conventional coatings:
3,000 to 4,000 shots before core pins failed

With FortiPhy:
one set of pins, still like new and going strong, with over 20,000 shots


See Other Injection Molding Success Stories with FortiPhy PVD-based Tool and Die Coating


Die Casting Success Stories about FortiPhy Corrosion Resistant Coating

Metal Forming Success Stories with FortiPhy High Performance Surface Coating

See Other Emerging Application Success Stories where FortiPhy Chromium-Nitride (CrN) Surface Coatings Have Helped.

 

 

 

Injection Molding Success Story

Custom injection molding company uses Phygen FortiPhySM chromium nitride (CrN) tool coating for improved mode release and corrosion resistance.

Not every company can succeed as a “custom” molder. When you receive an order, you use the customer's mold and your injection molding equipment, plastic, and skill to make a run of perfect parts. If the mold design is a little too “optimistic” and the scrap bins fill up, it's your problem. That's where experience and ingenuity pay off. If you can find a way to improve the performance of your customer's tooling, you do it, because it increases your productivity and profit.

Phygen CrN coating, tool coating helps custom injection molding company improve mold release and corrosion resistance.J.D. Products Inc., a custom molding shop in Vadnais Heights, MN, makes a variety of injection molded products for original equipment manufacturers (OEMs). J.D. produces a wide range of parts, from complex air filter housings and pharmaceutical accessories, to simple items such as plastic cattle tags. Its expertise and fast service keep J.D. in high demand throughout the Midwest.

Jim Denney Jr., plant manager, had a “nightmare” molding job that filled his shop's scrap bins for two years. A customer's complex mold had release problems that commercial coatings could not solve. Denney turned to Phygen for help. Now all plastic used for this job leaves the plant through the shipping department as finished parts. The scrap bins are empty. Experience has shown that FortiPhySM coatings by Phygen, with unmatched release characteristics, make “impossible” injection molding jobs not only work, but work profitably.

J.D. Products had a customer's mold that required several troublesome runs per year. The mold produces air filter housings that contain several barbs for attaching vacuum hoses. According to Denney, “One of these difficult contours, which also contains a core pin to form a tube, was causing some serious release problems. When the mold opened to eject the part, areas of the part would break off inside the mold, even with low-friction coating on the pins.” Instead of the core pin forming the tube ID and releasing from the plastic barb, the pin would stick — pulling out the barb and ruining the part.

Denney explains, “We struggled with this nightmare for two years. In addition to constant release problems, the best we could do was 3,000 to 4,000 shots before the coating wore off the core pins. We needed two or three sets of spare core pins and several tooling setup cycles just to make one run of 10,000 parts.” After struggling with commercial coatings, Denney turned to Phygen for a custom application of FortiPhy UltraEnduranceSM coating.

The key to the FortiPhy coating's exceptional toughness, low coefficient of friction, and corrosion resistance, is its uniform, nanocrystalline structure. Phygen’s patented plasma acceleration process improves upon traditional PVD techniques to produce the most uniform coating deposition layer possible, with exceptionally high adhesion. Having solved the uniformity problems inherent in the PVD processes of the past, Phygen can apply thinner coatings that outperform thicker, less-uniform coatings. In addition, Phygen coatings are applied at much lower temperatures. Low-temperature processing and thinner coatings help to keep critical tool dimensions within tolerance, without the costly rework of other processes.

How did Phygen improve the situation at J.D. Plastics? According to Denney, “Our release problem is solved and the coatings are staying on. So far, we have made a couple of large runs totaling more than 20,000 shots with no scrap parts, and without changing any core pins.”

J.D.'s productivity gains are a testimony to Phygen's advanced technology. In addition, Phygen's service will keep us coming back. Denney reports, “Their technical support was very informative and their turnaround time was great.”

Phygen Coatings, Inc.
1400 Marshall Street, NE / Minneapolis, MN 55413-1040
Toll Free 888.749.4361 / Fax 612.331.4230 / tech@phygen.com