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Mold Material We have experienced some challenges with thermal expansion differences between a manifold and an aluminum cavity, which can be dealt with, but are frequently a challenge. With the P-20 cavity and the manifold we avoid this and it still performs similar to a standard P-20 mold. Some mention potential for galvanic reaction between P-20 and aluminum, and while we have not seen this, it is recommended to spray the mold with a good grade of mold preservative prior to storage. Hybrid mold cavity repair and revision is no different than that of a conventional P-20 mold. On the other hand, the aluminum core is easy to weld or insert similar to a P-20 mold. Another advantage of the aluminum core is that in the P-20 mold the cavity is the half likely to see damage from flash as an unsupported surface. In the hybrid mold, it is more likely the core, which makes it easier to repair without cosmetic damage. Inserting the aluminum core is similar to P-20, but less consideration on cooling is necessary because of aluminum���s thermal conductivity. Hybrid molds will not withstand high pressure in the same way a complete P-20 mold will. Care must be taken to use the appropriate amount of clamp pressure to mold the part. Gas assist molds, both external and internal, are really great applications for hybrid molds as the core sees much less injection pressure than a conventional injection mold. Applying good molding practices is paramount for both types of molds, and identifying the mold material is key for a mold setter���e.g., paint an aluminum or hybrid mold a different color. Hybrid molds offer options for decreasing mold costs and cycle times. On average a part volume of fewer than 20,000 parts per year and 100,000 life would be a good candidate; although examples of EAU over 50,000 and 300,000 lifetime are possible. Part configurations are significant considerations. Intricate molds with a high number of mold actions would likely not be a good candidate unless the part volumes are low. Using a moldmaker with experience in hybrid molds is recommended to improve your success factor. contrIButor Roger Klouda is president of MSI Mold Builders. For more inFormation: MSI Mold Builders / (319) 848-7001 rklouda@msimoldbuilders.com / msimoldbuilders.com AMBA 2013 ANNUAL CONVENTION SCHAUMBURG, IL ��� APRIL 24-26, 2013 ���Operational/FinancialBenchmarkingData ���BestPracticesfromIndustryExecutives ���PlantTourWorkshops ���Peer-to-PeerExchangeForums ���SalesandMarketingStrategies Details on programming, registration and accommodations at www.amba.org. 38 MoldMaking Technology March 2013