MANUFACTURING PRACTICES
Stack Parts & Hot Runner Components-
- Cores, Neck Rings, Cavities & Gate Inserts are manufactured exclusively using Deutsche Edelstahlwerke (DEW) or Bohler-Uddeholm’s ESR grade Corrosion resistant martensitic stainless steel steel.
- Stack parts are rough machined, stress relieved & vacuum hardened to 50-52 Rockwell.
- Final dimensions are machined only after hardening to nullify any changes in dimensions during hardening.
- All mating surfaces (that experience wear) are cylindrical / surface ground for high precision and long life.
- Manufacturing is conducted in a temperature controlled room.
- Components are measured in-process by work-probing systems.
- Component are measured post process by highly accurate measuring instruments & gauges in a temperature controlled (standard) room.
- Tolerances on critical dimensions is maintained within +/- 3 microns.
Mould Base Plates-
- Mould base plates are manufactured from DEW or Bohler Uddeholm’s 1.2085 pre hardened corrosion resistant stainless steel with hardness of 30-34 Rockwell.
- Mould base plates, hot runner manifold & backing plates are rough machined and stress relieved before finish machining. This is to ensure that the dimensions of the plates do not change over time.
- At PETform, finish sizing, drilling & boring is done by jig boring class machines* only and never general precision CNC machining centers.
- In process gauging is used for eliminating errors and holding close tolerances.
- All plates are inspected on CMMs in temperature controlled (standard) rooms before assembly.
* jig boring machines are geometrically significantly more accurate than standard precision CNC machining centers. Jig borers have geometrical accuracies similar to measuring machines.
PRODUCTION INFRASTRUCTURE
All final machining takes place in an environmentally controller room (temperature is controlled at 25ºC +/- 1ºC)
CNC Lathes (11 units)-
- Hembrug Mikroturn 100CNC (Nano-Precision Turning Center)
- Hardinge Conquest 42 Super Precision Single Spindle
- Hardinge Conquest 42 Super Precision Dual Spindle
- Hardinge Conquest T65
- 3 x Jyoti CNC Lathes
- LMW Ultra Smart Turn
- Micromatic CNC Lathe
- Monforts KNC 5 Teach-In Lathe
- Traub 42/65 Dual Spindle Dual Turret Turn Mill Center
- Nakamura Tome TW20 MMY Dual Spindle Dual Turret Turn Mill Center
Cylindrical Grinders (5 units)-
- Kellenberger Kel-Varia with full B-axis & 2 external + 1 internal wheel (CNC)
- Jones & Shipman Universal Cylindrical Grinder
- 3 x Micromatic Universal Cylindrical Grinders
CNC Machining Centres (10 units)-
- 2 x Huron KX30 (1.8 m x 1.0 m travels)
- Dixi DPC 200 Horizontal Machining Center
- Makino V55 HSC Machining Center
- Makino V33 HSC Machining Center
- Mikron VCP 600 HSC Machining Center
- Mikron UCP 600 5-axis HSC Machining Center
- Jyoti VMC850 with 3+2 axis
- Jyoti RDX 20 with 3+2 axis
- Jyoti PX10
Jig Borers (8 units)-
- Dixi 75FE 4 Axis CNC Horizontal Jig Borer
- Hauser B3-DR
- Mitsui Seiki JIDC-5C CNC Horizontal Jig Boring Center
- Mitsui Seiki 6CNII CNC Jig Borer
- Mitsui Seiki 7CN CNC Jig Borer (1.53 m x 1.02 m travels)
- SIP 600 CNC Jig Borer
- SIP 8P Jig Borer (1.5 m x 1.0 m travels)
- SIP 5E Jig Borer
Gun Drilling Machines (2 units)-
- Buck TBFZ 1100
- Ixion TL1004
Surface Grinders (6 units)-
- Favretto 1,500 mm x 2,000 mm
- ABA 500 mm x 1,000 mm
- Blohm HFS9 400 mm x 900 mm
- Okamoto 50UDX 200 mm x 500 mm
- Jung HF50 200 mm x 500 mm
- Chevalier FSG 618 150 mm x 500 mm
- Jones & Shipman 150 mm x 500 mm
- Jung 540 150 mm x 500 mm
EDM-
- Sodick AL40G Linear Motor
Miscellaneous-
- Boehringer Copy Lathe
- Lagun FCM-1600 Milling Machine
- Alzarapid Radial Drilling
+ other miscellaneous machines
To see videos of machining operations, click here and scroll down.
Mitsui Seiki 7CN - Jig Boring of a 72 drop Stripper Plate

Huron KX30 - Milling of a 96 drop Cavity Plate

Huron KX30 - Milling of a 96 drop Core Plate

Buck - Gundrilling of a 96 drop Stripper Plate

Mitsui Seiki 6CNII - Jig Boring of 48 drop Hotrunner Manifold Front Plate

Dixi DPC 200 Horizontal Machining Center - Milling of Mould Base Plate

Dixi DPC 200 Horizontal Machining Center - Gun drilling of a Hot Manifold

Sodick EDM - Neck Ring Erosion


Traub Turn Mill Center (Double Spindle Double Turret)

\

Hardinge Conquest Super Precision Lathe for Hard Turning

Hard Turning of Core

Kellenberger Kel-Varia Universal Grinder
