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Frequently Asked Questions

1. How long is a typical injection cycle?
The molding cycle is dependent on the size and material section thickness of the component.  Typical cycle time ranges from 15 to 45 seconds and that can be for single or multi-cavity mold-sets.
2.  What are the best materials for the construction of the molds?
7075 Aluminum is well suited for mold-set manufacturing.  Aluminum offers excellent heat transfer i.e. short cycle times.  Aluminum mold-sets are relatively soft and care must be taken not to damage the cavity surface.  If the component to be
over-molded has steel components, it is recommended to have steel inserts in this area of the cavity.  This would be the case for connector over-molding.  Mold-set can also be manufactured from tool steel such as P-20.  It may be required to cross drill steel mold-sets to ensure sufficient cavity cooling.
What is the minimum tolerance that the Macromelt materials can hold?
The Macromelt materials shrink 1 to 2% depending on the grade of material.  This must be taken into account for critical applications.  Tolerances of +/- 0.1mm can be met on smaller components.
4. What is a typical injection temperature for these materials?
Melt reservoir temperature ranges from 180ºC to 230ºC.  Depending on mold-set design, this would typically correspond to cavity temperatures of 140ºC to 190ºC.
5. Can material regrind be used?
For applications where material mechanical and adhesive properties are critical, regrind should not be used.  The regrind material will always contain a minute amount of mold release agent, which could compromise adhesive properties. 
Furthermore the mechanical properties of the material will degrade somewhat from repeated re-melting.  For non-critical
applications the runners can simply be thrown back into the melt reservoir without any regrinding.  It is strongly recommended to confirm that component molded from “regrind” material meets the final component specifications.
6. Can the mold be plated to eliminate mold release?  
The Macromelt materials are adhesives and tend to stick to most surfaces.  It may be possible to use some coating for permanent mold release, but we can not recommend any coating at this time.
7. How do these Macromelt materials compare to engineered resins economically?  
Macromelt does not replace other plastic materials directly.  If a component can be molded successfully with PVC, there is no reason to consider Macromelt.  If PVC molding results in high scrap levels as result of high pressure, low pressure
molding may be more economical as result of reduced scrap.  More typically the low pressure molding operation replaces several manufacturing operations such as molding of a plastic housing and potting with epoxy.
8. Can batteries be over-molded without reducing their effectiveness?      
Many types of batteries have been successfully over-molded with Macromelt.  However, a simple prototype overmold for a particular battery is recommended before starting full scale production.
9. Is there any distortion of the final component with this process?  
No, not if normal design guidelines are followed.  (Uneven encapsulation such as a very thick material section on one side of a PCB with a thin layer on the other could result in warping)
10. Who will prototype my parts? 
3D CAD Modeling, Rapid Prototype Tooling, Rapid prototyping and Production Tooling is supplied by Tarapath as well as prototype parts when necessary.
11. Does Tarapath provide start-up training on moulding equipment?
Yes. Start-up and training typically takes 4 to 6 hours depending on the number of operators and machine model.
12. Who will provide technical support for the materials?
Tarapath will supply both material and application specific support.
13. What is the delivery time for materials? 
The OM product line is manufactured in Europe and warehoused in Melbourne.  We generally keep significant quantities of each material above forecasted volumes.  Accurate forecasts are critical as the lead time is 90 days for delivery from Europe to Australia. 
14. What is the delivery time for machines?
12 weeks approximately.
15. What is the delivery time for mold-sets?
Typically 4 to 8 weeks

 Please go to the next page for more detailed frequently asked questions

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