Case Study - Number 1


The challenges faced with this particular project where the over moulding of a complicated metal fabrication that was only 0.3mm thick whilst maintaining tight tolerances of + or - 0.02mm, this coupled with having a restricted feed position and warpage having to be kept to a minimum using a crystalline material set a task that tested all aspects of both the tooling & moulding processes.

Lead Time: Add Dates Here
APQP: Required
Part Spec: Nylon 6
Mould Flow: Required
Tool: Fully hardened tool
3D Model: Not Required
Summary: This part is for our own product range and the reason we decided to feature it is because it has 3 different sets of inserts that we can change on the press so we have no down time. It means basically that 1 part can make an additional 2 variants.
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Case Study - Number 2


The challenges faced with this particular component where not only the thread form requirement but also the interchange ability of the pin configuration from 5 - 8 hole.
The tool had to be designed in such a way that we could change the pin configuration with ease but also get sufficient cooling around the thread area to maintain the tight tolerance requirement.
To overcome this we manufactured Trojan alloy core pins to run through the centre of the unscrewing core, this gave us the ease of interchange ability, cooling requirement for the thread and provided the lubrication requirement for the unscrewing core to rotate around the pin.

Lead Time: Add Dates Here
APQP: Required
Part Spec: Nylon 6
Mould Flow: Required
Tool: Fully hardened tool
3D Model: Not Required
Summary: This part is for our own product range and the reason we decided to feature it is because it has 3 different sets of inserts that we can change on the press so we have no down time. It means basically that 1 part can make an additional 2 variants.
Injection Moulding Design - Case Study
Case Study 2 Tool making
Injection Moulding Design - Case Study

Case Study - Number 3


Project Background Overview

Patterson & Rothwell, as leading toolmakers and injection moulders was approached to offer a solution to the growing number of product rejects, recalls and bottlenecks within their manufacturing area. This was caused by the gradual decline in product quality that was being produced by a worn and poorly made injection mould tool from one of their long term suppliers.

Design Brief.

The part is a medium to high volume part and as such became a multi cavity tool. In addition, an unscrewing mechanism, which created a thread within the part needed to be designed in (please see pictures). To complicate matters further this area required inserting to allow for a non-threaded option, so one tool could manufacture both products therefore reducing the cost of two tools. As the parts interacts with another part, care had to be taken during the design process to allow for the shrinkage rates of the different materials utilised.

Test Criteria.

The product had to be able to withstand winter and summer temperatures yet does not warrant the luxury of engineering materials due to market price restrictions. The objective was to source a commodity material that was tough but not brittle when cold yet retaining its strength at higher temperatures.

Lead Time: Add Dates Here
APQP: Required
Part Spec: Nylon 6
Mould Flow: Required
Tool: Fully hardened tool
3D Model: Not Required
Customer satisfaction: Since the completion of this project the injection mould tool is now fully operational 24 hours each day and for 5 days a week. Customer bottle necks are now reduced, and machine efficiencies are now 100%.
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P&R Case Study 3
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