Step 1. Pre-project activities. Each project starts with the idea of the desired product or part, the sample, drawing, or technical specifications of it. At this stage, Spetztekhosnastka project manager develops the project proposal, presenting time and costs estimations for the injection mold design and production. Upon contract negotiation and its approval, Spetztekhosnastka project team develops a detailed production schedule, enabling the parties to track the advancements in the mold production.
Step 2. Injection mold design. Spetztekhosnastka Design Bureau consists of 17 highly qualified design engineers. Based on the approved technical specifications and schedule, the designer develops 3D models and mold drawings using the SOLIDWORKS application. Communication with the customer and design endorsement by the customer is a part of this process. All information related to the approved design, any changes and corrections made, are archived, and allow Spetztekhosnastka to manufacture any spare parts during all time of mold operation in the future.
Step 3. Procurement. Upon final approval of the mold design, all needed materials and components are ordered by the procurement service. Spetztekhosnastka Tooling Shop uses BOHLER steels, AMPCO bronze, THYSSEN KRUPP aluminum alloys to produce mold parts. In addition to the mold parts manufactured by Tooling Shop, the mold consists of standard components as well. Spetztekhosnastka obtains standard elements and systems from well-known manufacturers and suppliers such as DME, HASCO, HUSKY, STRACK, VEGA, BOLEX, FIBRO, and others.
Step 4. Production. The Spetztekhosnastka Tooling Shop produces the mold components based on the 3D models and 2D drawings supplied by Design Bureau. About 60 skilled workers operate a variety of metal cutting equipment, including 16 CNC machines. Equipment is composed of universal turning and milling machines, vertical and radial drilling machines, surface grinding and cylindrical grinding machines, coordinate boring machines, and others. For electrical discharge machining (EDM) are used wire cut EDM and die-sinking EDM by CHARMILLES (Switzerland). CNC Machining Centers by top European manufacturers such as DMG (Germany), HERMLE (Germany), TAJMAC-ZPS (Czech Republic) can process parts in three axes and five axes. CAM programs are developed with the PowerMILL Pro application by Autodesk.
Step 5. Heat treating. For many years Spetztekhosnastka uses the vacuum furnace to achieve desirable outcomes in steel normalizing and hardening. Our heat-treating unit is equipped with SECO / WARWICK 10.0 VPT-4025/24 vacuum oven.
Step 6. Grinding. Hardened parts are processed on the grinding machines. Spetztekhosnastka Tooling Shop is equipped with various types of grinding machines and has decades of professional expertise. Round outer, round inner, flat, profile, and thread grinding operations are performed with high precision.
Step 7. Electro erosion. One of the technological operations of high accuracy is electro-erosion treatment (EEO). Spetztekhosnastka has been successfully using it since 1995 in the cases when traditional methods of metal processing are not sufficient for achieving the desired result.
Step 8. Measuring. Parts’ dimensions are controlled by the Measuring Laboratory of Spetztekhosnastka Tooling Shop, equipped with modern CMM, e.g., coordinate measuring VISTA (Carl Zeiss), video measuring Scope Check (WERTH), coordinate measuring Scope Check MB (WERTH) with profile and surface scanning. At workplaces, workers use universal measuring instruments as well as TESA electronic meters, ETALON micrometers, Mahr calipers, TESA calipers of various types and sizes.
Step 9. Assembly. Spetztekhosnastka Locksmith area is a place where hundreds of manufactured and purchased parts are put together into a finished mold. Skilled and experienced toolmakers check and polish parts, and assemble the mold, ensuring the reliability of all components and systems.
Step 10. Testing. Testing the mold on an injection-molding machine is an essential step in the production of mold. We use modern western European machines produced by DEMAG, ARBURG, and HUSKY to check the ease of installation and removal of the mold; the correctness of connections and accuracy of injection, thermal stabilization, ventilation, protection system; parts movement through pneumatic and hydraulic cylinders, the correctness of functioning of the hot runner system. The testing is performed both in setup mode and in serial production mode according to parameters required by the customer.
Step 11. Serial Production. In many cases, the molds, produced by Spetztechosnastka, remain at our premises and are used for serial production of plastic packaging and plastic parts manufacturing for the needs of our clients. Over the years of production, we have become reliable partners for a large number of companies, including such well-known names as RAVAL, Premium Sound Solutions, SodaStream, Kostal, DANONE, TRIORA, Agrinol, MGF, Kompozit, Dufa, ZIP, Torchyn, Schedro, Olis, Olkom.
