Feature Article - Getting the Right Finish For Your Mold: It Takes More Than Just Brute Strength

FEATUREARTICLE

Getting the Right Finish For Your Mold: It Takes More Than Just Brute Strength

By Steven J. Bales

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For more information contact Bales Mold Service, Inc. (Downers Grove, IL) at (800) 215-MOLD.

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It was once thought that professional mold polishers were the men with the strongest backs and the weakest minds. Yes, it takes some amount of strength to put the right finish on steel, but today more than ever it also takes an in-depth understanding of the craft, the materials used and a solid working relationship between the polisher and his customer.

With the ever-increasing capabilities of the modern tool shop, the advances in technology and the fertile minds of designers, most toolmakers are able to specialize. The possibilities are endless for close tolerance, intricately designed molds that need polishing to finished specs by a mold polisher who also can be considered a specialist.

The ultimate goal? Working together, it can be on-time delivery of a precisely built, beautifully polished mold that reproduces exact parts, be they the first or the millionth.

Communication Is Key
How do you achieve this result consistently? Clearly, the key is communication. Look for a polisher who is willing to listen to his customer and give the kind of valued input that can make the difference in the quality of the end product. You wouldn't give your car to any repair shop and just say "fix it" without first ensuring yourself that the mechanic is experienced in working on your kind of vehicle. Similarly, no moldmaker who is proud of his work would give his mold to just any polisher and say "polish it." Nor would a polisher, who cares about his customer, take a job that way.

Get The Specs
It is up to the polisher to get the information that he needs to perform his job to the standards and expectations of the customer.

For instance, a job calling for a 320 stone finish would not require the polisher to know that the mold is built with stainless steel. On the other hand, if that same mold were to be diamond polished, he would want to know it was made with stainless steel because it polishes differently than if the mold were made from another grade of steel. The polisher must ask the right questions, up front. A marked blueprint is a helpful road map to success-as is an exact piece part. Any information a toolmaker can provide to his polisher is his assurance that the job will be done right the first time.

Preparation Saves Time and Money
It is surprising to see how often a tool is sent out for polishing without proper preparation. Nothing can waste time and money faster than this, and it is really a simple problem to solve.

The time and money it takes to get the best quality finish depends on the quality of the finish on the tool to begin with. Whether a mill, lathe or EDM is used, take a little extra time to slow down the feed of the tool so that a smoother surface is created. This little "head start" will result in less time and effort on the part of the polisher and can make all the difference in the subsequent time and expense incurred on the project.

From Start To "Finish"
Polishing should be considered throughout the mold building process from the design stage through to molding. If polishing details are left out until two weeks prior to delivery, the hard work and time your shop put into the mold, not to mention your impending profit, could be in jeopardy. Why? Today's molds demand consistent, high quality finishes executed by highly-skilled professionals. Adequate time is needed to evaluate the project and perform the services needed.

In summary, the key to getting the right finish for your mold depends upon:

Planning - Include polishing details from design through molding. Your polisher should be willing to consult with you so you'll know the timing and requirements involved to ensure a quality outcome.

Communication - Give and ask for the information needed to ensure your mold is in the right hands.

Understanding - Know what it takes to produce the finish you need on your precision-built, American-made tool.

The United States has always set the standard in the mold building industry. It's a certainty that molds are only going to get more technically challenging, requiring continued advancement in the mold polishing industry as well. Setting that standard higher and never settling for "good enough" will keep us on top. But it takes mutual respect and cooperation between toolmakers and polishers. Together we can fight against the influx of "good enough" tools.