inherited a customer’s problem P20 molding tool that was never able to run correctly, much less efficiently enough to justify the exorbitant cost of $125,000. This particular Mold was completed with 4 cavities, a hot runner system and cavity detail that was “Cut in Solid”. “Cut in Solid” means that you basically “get what you get” with no adjustments, and as is. On top of that issue, the P20 Mold was a very large one as was 4 feet high. A large tool like that would require a 400 Ton press. The actual component was the size of a bottle cap, about 1 ½ inches in circumference. That is an enormous amount of wasted material; a guesstimate would be ½ ton worth of unused P 20.
The size of the injection molding press needed was also overkill in the injection molding best known practices. Generally for cost savings, the smallest sized injection molding press is used. Especially for small parts that even as a family tool could be built to run in a much smaller injection molding press.