Scientific Molding

C. Brewer Company's Scientific Molding techniques define and bring order to the molding process by taking advantage of the physical properties of plastic to deliver a repeatable system for consistently moving the same volume of material at a tightly controlled velocity.

Plastic does not behave like any other fluid; viscosity decreases (it flows easier) as velocity increases. Scientific Molding techniques qualify the mold to a single process. They establish fixed values for the four most important variables in the molding process:

C. Brewer Company has developed a documented procedure where we define, via test, four pillars that support the successful execution of the Scientific Process Development of every mold.

A TIME (flow rate) study creates a viscosity and shear rate curve using the mold and machine to determine optimum fill time. This curve is unique to each mold and provides a range of velocities that will deliver a robust process yet allowing "lot-to-lot" variability in the materials melt index.

A TEMPERATURE study measures the actual melt temperature of the material and actual surface temperature of the mold via a pyrometer. Therefore, future processes are based upon actual values rather than the variability caused by the machine.

A PRESSURE gradient study graphically illustrates the pressure drops as the material transitions from the molding machine through the mold and ultimately to the cavity. This is a diagnostic tool that provides confidence of fill. Molds equipped with pressure transducers provide the added benefit of optimizing packing pressures.

A COOLING map identifies the temperature and volume of coolant "In and Out" of the molds cooling channels. This map defines the cooling efficiency and provides a template for repeatable set-ups and a history for future comparison.

These four pillars provide documented data that determine the appropriate adjustments to the mold. The mold is optimized to support the Scientific Process using data from these studies, capability studies, First Article Inspection Reports and Gauge R&R’s. Tool steel dimensional audits determine the final adjustments that are made so the mold supports the optimized process.

C. Brewer Company's Scientific Development Process delivers a unique Time (Flow Rate), Actual mold and melt Temperature, Pressure Gradient, and Cooling studies. These diagnostic tools correlate with a documented molding process, proven to deliver the highest CPK for critical dimensions. The combined use of these tools supported by the dimensional data provides statistical confidence of a repeatable process. In addition, Scientific Molding delivers faster molding cycles, higher yields, compressed process qualification and a more robust injection molding process.

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C Brewer Co.

3630 Miraloma Avenue Anaheim, CA 92806

(714) 630-6810