AES molds

Services

Since the beginning of AES Moldes, in the year 2001, we identified the need to bridge traditional mold making with a mold ready for production. To fulfill that vision, we clearly established a list of specific services to address that need.

Project Management:

Project Management:

When given a project, a senior project manager will be assigned to it. From that point on, the senior manager will be your main contact from the beginning of the project until the shipment of the mold. Our project managers are mechanical engineers with at least 10 years of experience in the mold making / plastics industry. He/she will be fluent in English, Spanish, and French; listen to your needs and to our team's needs; and will be able to provide you and our internal team with solid and sound solutions. Among others, some of the advantages our customers would benefit from are:

  • Single point of contact with no language barrier
  • Constant availability regardless of what time zone you're in
  • Weekly progress reports with pictures if needed
  • Formal process control with reports for design evaluations, critical dimensions, samples, etc.
Product Design Engineering:

Product Design Engineering:

We can take your idea from a sketch or from an existing basic concept to a fully engineered 3D model.

If your idea is already fully engineered in a 3D format, we will always try to bring our moldmaking and production experience to make your product even more robust and effective to the manufacturing process.

To minimize cost and timeframe, it is always beneficial that you let us be involved with your engineering group as early as possible in the process. Let us be part of Early Supplier Involvement (ESI) with your team.

Our team can perform the following:

  • Mechanical Design
  • Solid Modeling
  • Structural analysis
  • Feasibility analysis for plastics manufacturing
  • Feasibility analysis for mold manufacturing
  • Prototypes – SLA, SLS, Machined parts and Urethane molds
  • Prototype molds
Mold Design & Tooling Engineering:

Mold Design & Tooling Engineering:

Within our technical group, we have the combined experience of 100 years of mold design engineering and mold manufacturing experience.

Experience combined with state of the art technology is one of the reasons AES makes a difference, and our molds show it. For all the molds we build, the following comprehensive engineering studies are performed by our tooling engineers:

  • Mold Flow Analysis
  • Draft analysis
  • Wall section analysis
  • Parting line development in conjunction with our customers
  • Gating and Ejection location development in conjunction with our customers
  • Multiple iterations of Mold flow studies
  • Cooling optimization
  • Preliminary mold design concepts
  • Tool manufacturing strategy development for smoother tool validation process
  • Full 3D mold design
  • Detailed mold components (2D & 3D)
Mold Manufacturing:

Mold Manufacturing:

Our molds are manufactured within our group of fully qualified tool shops including our own internal tool shop - AES Manufacturing. The equipment within our manufacturing group is the latest state of the art manufacturing equipment in order to guarantee the quality levels required by our customers.

Ninety percent of the molds that we build are class 101 molds: a life guarantee of over 1 million shots. These molds are fully hardened, using the best hot runner systems and the best components available in the market. Look at the testimonials from some of our customers that talk about one of our molds that has been in consecutive production for over 8 years.

We also have the capability of building prototype molds in aluminum that could produce up to 100,000 shots, pre-hardened bridge molds that are good for 500,000 shots, and fully hardened molds that are good for over 1,000,000 shots.

Our experience in mold design and mold manufacturing covers the following mold technologies:

  • 3 Plate Molds
  • Molds for Multiple Part Versions
  • Un-screwing Molds
  • Insert Molds
  • Vertical Molds with Multiple Ejector Halves
  • Two Shot Molds – Rotating Platen or Internal Indexing Plate
  • Core Back
  • Stack Molds
  • In Mold Closing
Mold Qualification:

Mold Qualification:

Our molds are all fully tested, developed and validated before they are shipped to our customers. This qualification begins with a full mold mechanical validation at the injection machine, followed by a scientific injection process development using RJG or Kistler pressure transducer (if installed in the mold), and finally to a full plastic part / mold dimensional approval. We use our metrology lab, our Edart controller from RJG, and our Kistler controller to their fullest capabilities.

Our comprehensive mold and part development studies performed by our engineers cover:

  • Tool Mechanical Tests
  • Basic Injection Process Development
  • Scientific Injection Process Development
  • DOE Studies
  • FAI/ISIR Studies
  • Capability Studies: Cp and Cpk Studies
  • Steel dimensional extrapolation and mold Steel Adjustment
Metrology Laboratory:

Metrology Laboratory:

Our in-house metrology lab includes a fully programmable Zeiss CMM machine, vision systems, photometry capabilities and other conventional measuring equipment. Our process is designed in a way that the measuring programs are done before the mold is constructed. This allows us to have dimensional results on plastic parts within 48 hours a mold sample.

Our services and capabilities include:

  • First Article Inspection (FAI)
  • Photometry Dimensional Inspections
  • Capability Studies, Cp and Cpk
  • Visual Inspections
  • Gage R&R
  • Steel Safe Measurements
  • Design of Experiments (DOE) inspection
  • Custom Fixturing
Fixture and Guage Development:

Fixture and Guage Development:

To provide an integrated production solution to our customers we also develop and manufacture the following solutions:

  • Gauges for Production Control
  • Measuring Fixtures
  • End of Arm Tooling
  • Special Components Manufacturing