Aerostar Manufacturing
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PortfoliosCNC Machined A357 T6
Aluminum Axle Housing
CNC Machined Lube Oil
Filter Head Casting
CNC Machined Aluminum
Sand Cast Engine Control
Valve Assembly
Hard Turned Tool Steel
Actuating Cam
CNC Machined Fan
Hub Assemblies
CNC Machined Sand Cast
Ductile Iron Differential Case
Dry Spindle for High
Speed Centrifuges
24" Dia Wire Feed Pulley
Stainless Steel CNC

Plastic, Injection, Blow, Foam Mold & Pattern Making

Plastic Mold & Pattern Making

(Click on pictures to enlarge)

We produce custom molds for prototypes and low volume production runs. Our extensive molding capabilities include injection molding, blow molding, compression molding, and transfer molding. We can also produce custom vacuum form tooling suitable for making small as well as large products.

Depending on your production or prototyping requirements, molds can be manufactured to utilize materials such as plastic, nylon, polypropylene, and rubber. Aerostar Machining, Casting, Prototyping Group constructs a variety of molds for parts used in the automotive, agricultural, and mining industries. Through rapid prototyping, we assist customers in finalizing their actual product designs quickly.

Our current mold process types include:

  • Blow molding
  • High pressure tonnage
  • Solid
  • Over molding
  • Foam molding

With in-house mold designing, prototyping, CNC machining, and casting capabilities, Aerostar offers one-stop solutions for all your custom mold construction needs. As your molding partner, we can manufacture molds in custom shapes and sizes, while maintaining tolerances close to 0.002".

Plastic Mold & Pattern Making Plastic Mold & Pattern Making Plastic Mold & Pattern Making
 
Plastic Mold & Pattern Making
Plastic Mold & Pattern Making
Plastic Mold & Pattern Making

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Portfolio (View Examples of our Work)

Specifications

General Capabilities Contract Manufacturing
Custom
Large Parts
On-Site
Small Parts
Prototypes

Industry Focus Agricultural
Automotive
Heavy Truck
Off Highway
Chemical
Food
Machine Tool
Marine
Military
Energy
Environmental
Packaging/Converting
Power Generation
Lighting
Mining

Industry Standards ANSI (American National Standards Institute)
ASME (American Society of Mechanical Engineers)
ASTM (American Society for Testing and Materials)
ISO (International Organization for Standardization)
  • ISO 9002
  • ISO 9001:2000
Mil-Spec (Military profications)
NMSDC (National Minority Supplier Development Council Certified)
NAIC (National Association of Insurance Commissioners)
  • 541614
  • 541330
RoHS (Restriction Of Hazardous Substances Compliant)
TS (Technical profications, used with ISO 16949)

Materials Plastics
Nylon
Polypropylene
Acetol
Thermo Plastics
Urethane
Rubber

Molding Process Injection Molding
Low Pressure Injection Molding
Blow Molding
Compression Molding
Transfer Molding
Open Pour Foam

Production Volume Prototype to Low Volume

Additional Services Provided Assembly
Mold Design
Rapid Prototyping
Casting
CNC Machining

File Formats AutoCAD (DWG,DWZ)
BMP (Bit Mapped Graphics)
Catia (CATDrawing,CATPart)
DXF (Drawing Interchange Format, or Drawing Exchange Format)
GIF (Graphics Interchange Format)
IGES (Initial Graphics Exchange profication, ANSI file format)
Inventor (IDW, IPT)
IronCAD (ICD,ICS)
JPG or JEPG (Joint Photographic Experts Group)
MasterCam (MDX, MC8, MC9, SET)
PDES (Product Data Exchange using STEP, Standard for the Exchange of Product Model Data. A standard format for exchanging data between advanced CAD and CAM programs)
PDF (Portable Document Format)
Pro-E or Pro/Engineer (DRW,PRT,XPR)
SAT
3D ACIS Model File
SolidEdge (DFT)
SolidWorks (SLDPRT,SLDDRW,SLDDRT)
STEP (Standard for the Exchange of Product Model Data)
SurfCam (DSN)
TIFF (Tagged Image File Format)

Tolerance (+/-) ±0.002 in
±0.051 mm

Injection, Blow, and Foam Molding

As a premier provider of custom injection, blow, and foam molding services, Aerostar features an array of molding options for industries ranging from aerospace and military to consumer goods and communication. We’re capable of working with small, large, and multi-part components for various intended applications, such as automotive foam and window components, and we feature over 14 foam materials. Our current mold process types include:

  • Blow;
  • High press tonnage;
  • Solid;
  • Over molding; and
  • Foam molding.

In addition to these processes, Aerostar proudly offers engineering, mold making, product development, rapid prototyping, and tooling services. For more information on starting your next project, contact Aerostar.

General Capabilities Custom

Industry Focus Aerospace
Automotive
Building
Communication
Consumer Goods
Electrical
Electronic
Maritime
Medical
Military
Optical

Intended Application Components
Furniture Foam
Automotive Foam Components
Blow Molded Ducts and Air Intakes
Window Components

Industry Standards ANSI (American National Standards Institute)
ASME (American Society of Mechanical Engineers)
ASTM (American Society for Testing and Materials)
ISO (International Organization for Standardization)
  • ISO 9002
  • ISO 9001:2000
Mil-Spec (Military Specifications)
NMSDC (National Minority Supplier Development Council Certified)
NAIC (National Association of Insurance Commissioners)
  • 541614
  • 541330
RoHS (Restriction Of Hazardous Substances Compliant)
TS (Technical Specifications, used with ISO 16949)

Material ABS
Acetal
Acrylic
Copolymer Polypropylene
HTPE/LDPE
Microcellular
Nylon
PEEK
PET
Polyaryletheretherketone
Polycarbonate
Polyester
Polypropylene
Polystyrene
Polyurethane
Thermoplastic
Thermoset

Product Capabilities Large Components
Multi-Component
Small Parts

Mold Process Type Blow
Method of fabrication in which a warm plastic hollow tube is placed between the two halves of a mold cavity and forced to assume the shape of that mold cavity by use of internal pressure.
This process forms hollow articles such as bottles, tanks, etc.
High Press Tonnage
An Injection Molding Machine that exerts very high clamping forces. These machines are usually used to produce larger parts.
Solid
A process to manufacture solids parts that do not have any hollow cavities.

Over Molding
Foam Molding

Additional Services Engineering
Mold Making
Product Development
Rapid Prototyping
Tooling

Production Volume Prototype to High Volume

File Formats AutoCAD (DWG,DWZ)
BMP (Bit Mapped Graphics)
Catia (CATDrawing,CATPart)
DXF (Drawing Interchange Format, or Drawing Exchange Format)
GIF (Graphics Interchange Format)
IGES (Initial Graphics Exchange Specification, ANSI file format)
Inventor (IDW, IPT)
IronCAD (ICD,ICS)
JPG or JEPG (Joint Photographic Experts Group)
MasterCam (MDX, MC8, MC9, SET)
PDES (Product Data Exchange using STEP, Standard for the Exchange of Product Model Data. A standard format for exchanging data between advanced CAD and CAM programs)
PDF (Portable Document Format)
Pro-E or Pro/Engineer (DRW,PRT,XPR)
SAT
3D ACIS Model File
SolidEdge (DFT)
SolidWorks (SLDPRT,SLDDRW,SLDDRT)
STEP (Standard for the Exchange of Product Model Data)
SurfCam (DSN)
TIFF (Tagged Image File Format)

Shot Size
The maximum weight of plastic that can be displaced or injected by a single injection stroke. Generally expressed as ounces of polystyrene.
Max - 100 oz.

Clamping Force Max - 150,000 tons

Number of Cavities
The number of cavities in the mold used to produce multiple products in one molding cycle.
Min - 1 cavities Max - 10 cavities

Tolerance (+/-) .005 in.

Reference:

http://www.daprorubber.com/Prototyping.aspx

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