NyproMold, Inc., one of the industry’s largest suppliers of precision molds, displayed its latest technologies at NPE 2012 including high precision molds, inserts, and components, that showed the company’s expertise in the major markets it serves including healthcare, packaging, and consumer electronics.
In addition, the company announced that it has introduced CT-scanning to its suite of metrology services. This technology produces fast, precise 3D representations of parts both internally and externally, allowing easy metrology evaluations that were previously technically difficult and time consuming to achieve.
“We believe we are the only mold maker in North America to have this capability,” said Bill Muldoon, President of NyproMold. “It provides detailed information on a part or assembly that was previously either unattainable or extremely difficult to obtain, and allows us to make decisions that allow us to build qualified molds faster than ever before.”
“Getting good data to analyze parts quickly and accurately during the development/testing process is critical to making the right engineering decisions during mold development,” he said.
CT Scanning for Plastic Parts
CT scanning is a process that uses an x-ray scan to produce a complete highly accurate 3D representation of the component.
Using CT scanning, NyproMold can nondestructively visualize, measure, and analyze an application all at the same time and get results quickly with unparalleled accuracy. CT scanning services can be performed on individual parts as well as on complete assemblies and devices. NyproMold’s CT scanning services include part to CAD model comparison, a service called FASTscan. The scan output is a 3D visual map of the molded part geometry overlaid and compared to the original CAD database. Also available are part quality and dimensional analysis, part-to-part comparison, and reverse engineering. In all cases, the customer will receive an integrated viewer for easy review of the data results.
Tom Casali, manager of the NyproMold Technology Center, says during initial mold trials, FASTscan is used to confirm that the centerline molding process has been achieved and provides the customer the most accurate dimensional results as compared to traditional metrology techniques. “FASTscan verifies the alignment between molding capability and molding quality, and gives us added confidence going forward with a full first article inspection,” he explains.
FASTscan: Part-to-CAD Comparison
NyproMold has incorporated CT scanning into the mainstream of its development processes. Using an internally developed process called ‘FASTscan’, 100% dimensional feedback is obtained very early in the testing process. FASTscan is a comparative analysis from the CAD model to the scan of the molded component. Typically in less than two hours, this service creates a precise overlay of the scanned data set to the original 3D part model database. The color-coded, easy-to-interpret display of a geometry comparison quickly and clearly provides meaningful information about the dimensional stability of the entire component. Using an integrated viewer, the customer can easily determine the part’s dimensional deviation from nominal.
Similar to FASTscan, part-to-part comparison provides an overlay of two scanned parts, which allows for quick identification of dimensional deviations between the parts. These parts could represent process 1 vs. process 2, archived parts vs. new parts, or parts produced from two different molds. Using an integrated viewer, the customer can easily analyze a color variation chart showing the deviation from one part to another preselected reference part.
Void and Inclusion Analysis
This service will provide material and defect analysis showing void or inclusion size and locations.
Wall Thickness Analysis
Conventional metrology techniques often require destructive slicing in order to access areas within complex parts. With complete 3D model generation, the color-coded display allows you to quickly and accurately measure slight changes in wall stock of complex parts without destructive testing.
CT scanning applies to complete assemblies and devices and produces a 3D image that can be manipulated to show hidden components and internal assembly. Complicated assemblies can be reviewed and critiqued at levels previously unavailable, showing seals, fits, interface engagement, interferences, etc.
Just like with traditional CMM techniques, CT scanning can produce full first article inspections and provide a dimensional report, but often cheaper and faster than CMM.
A 3D CAD file can be generated and exported from the CT scanned dataset quickly and accurately.
NyproMold delivers value with optimized mold solutions using industry leading technologies and techniques providing improved speed to market, faster cycles, higher quality parts, and longer mold life.
The company is headquartered in Clinton, MA, and has a Midwest manufacturing facility in Gurnee, IL.
For more information on NyproMold, contact Jennifer Raymond, Business Development Manager, at +1-978-368-5335, or visit www.nypromold.com.