Introduction to Mold Textures in CNC Machining(rivet in metal Lindsay)
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One important consideration when CNC machining a mold is the surface finish and texture. The texture of the mold surface can significantly impact the look, feel, and performance of molded parts. By controlling surface roughness, patterns, and textures, CNC machined molds can impart specific aesthetic qualities and functional properties to finished products.
This article will provide an overview of common mold surface textures achieved through CNC machining processes. It will explain the benefits of different mold textures, how they are produced, and applications where intentional mold texturing is advantageous.
Reducing Surface Friction with Polished Finishes
A polished surface finish is a smooth, mirror-like texture free of visible machining lines. Polished CNC machined molds have a glossy appearance and an extremely low surface roughness, usually under 10 microinches.
Polishing is achieved through a multi-step abrasive process after initial rough machining. Fine abrasive compounds and polishing wheels are used to level peaks and valleys in the surface until the desired uniform smoothness is attained.
The main benefit of a polished mold finish is the reduction of surface friction. When molds have a polished finish, molded parts can be more easily released without sticking or tearing. This allows faster cycle times and less wear on molds over time.
Polished finishes are ideal for plastic parts with intricate geometries and molded rubber products where release is challenging. The glossy aesthetic of polished molds also imparts an attractive luster and shine to finished goods like toys, consumer electronics, and automotive components.
Simulating Appearances with Textured Finishes
While polished finishes are optimal for release and friction, textured surfaces can replicate appearances and feels of other materials. By controlling surface patterns, CNC machined molds can mimic looks ranging from the visual grain of wood to the coarse texture of cast metals.
Common texture patterns include diamond knurls, lines, checker plates, grains, meshes, and custom logos. Textures are generated through CNC programs directing the movement of cutting tools. Parameters like tool stepover distance, angle, and overlap are adjusted to obtain the desired depth, spacing, and consistency of the texture.
Textured molds impart decorative qualities to products across many industries. For example, a wood grain texture can be added to molded furniture accents or dashboard components. Diamond plate patterns give a tread plate metal aesthetic to trim parts. Using textures to emulate appearances allows plastic to be an alternative to wood, metal, and other materials in certain applications.
Improving Grip and Ergonomics with Rough Finishes
While polished molds focus on smoothness, rough surface finishes are implemented when more friction is beneficial. Intentionally rough mold textures can enhance grip, tactile feel, and ergonomics for products like handles, grips, taps, and consumer goods.
A common technique is a directional finish like molded-in knurling. Angled ridges are cut into the mold surface using a knurling tool. The ridges provide aligned micro-lines and grooves to increase grip and friction in specific directions. Users can get a better hold on knurled handles for tools, sporting equipment, and appliances.
Media blasting is another process used to roughen mold surfaces if desired. Fine abrasive particles are propelled at high velocities to uniformly abrade and matte the mold material. This creates a coarse, dull surface profile compared to the sheen of polished finishes. The peened surface provides a tactile quality and secure grip.
Facilitating Post-Molding Operations with Satin Finishes
While very smooth or very coarse finishes have benefits, a medium satin surface can also be advantageous. Satin mold textures are slightly dulled polish finishes with some microscopic roughness intact.
The moderate amount of texture facilitates post-molding processes like pad printing, painting, plating, bonding, and decorating. Satin CNC machined molds provide an appropriate amount of “tooth” for coatings and finishes to mechanically adhere. The low-reflectivity satin appearance also contrasts nicely with decorative paints and prints.
Common applications using satin mold finishes include plastic housings needing decorative finishes, overmolded parts getting additional coatings, and components requiring selective textures in different areas. The satin surface accepts secondary processing well while allowing demolding without excessive friction.
Using Mold Textures to Control Part Appearance and Performance
In summary, manipulating surface textures when CNC machining molds provides extensive control over the end product’s aesthetic qualities and functionality. Polished molds maximize release while textured molds can precisely simulate a material appearance. Rough finishes enhance grip and medium satin textures support downstream processes.
With computer programmed numerically controlled tools, very specific surface roughness and repeatable patterns can be achieved through parameter dialing and toolpath optimization. Mold texturing expands the design possibilities for plastic, rubber, and composite parts while improving manufacturability. Combined with CNC machining’s accuracy and efficiency for producing molds, textures enable high performance injection molded components with engineered cosmetics. CNC Milling CNC Machining