Professional Documents
Culture Documents
Ikea Mould Standard 2015-02-25 5.2
Ikea Mould Standard 2015-02-25 5.2
CONTENTS
1. OVER ALL INFORMATION
2. PARTING LINES AND ORIENTATION OF PART(S)
3. UNDERCUTS
4. DRAFT ANGLES
5. PLACEMENT OF GATE(S) AND FLOW ANALYSIS
6. RUNNER SYSTEM
7. VENTING
8. TEMPERING
9. EJECTION
10. STEEL AND OTHER MATERIAL(S)
11. MOULD BASE AND ACCESORIES
12. TOLERANCES AND MEASUREMENTS
13. SAFETY
14. LIFTING OF MOULD & MOULD PARTS
15. MOULD MARKING
16. PACKAGING, DELIVERY, HANDLING
17. MAINTENANCE
18. DOCUMENTATION
19. MOLD PERFORMANCE TESTS
1. OVERALL INFORMATION:
1.1. No exceptions from this mould standard are accepted unless written consent
by IKEA.
1.2. Responsibility of the mould design, expected life time acc to IKEA Mould
Assignment and assurance of fulfilment of the requirements for the article /
product lies with the product supplier of IKEA.
1.3. All moulds (base) shall be painted in colour IKEA Blue: NCS 4550-R80B.
2.3. Consider the function and visibility of the different areas of the part and
design the mould so the most visible part is not subjected to marks from
ejector pins and other moving parts of the mould.
Moveable half
The thin blue line illustrates with ejector
the parting line marks.
3. UNDERCUTS:
3.1. Identify the undercuts and solve them as simple as possible. For instance
they might be made with no moving parts if the part is oriented in a suitable
way (without disturbing other functions).
3.2. Normal undercuts, such as holes through the parts walls, should, if possible,
be driven by angled pins with an angle not succeeding 15°. The sliders must
have a support with an additional angle of 2°.
3.3. Longer movements can be driven by hydraulic- or pneumatic cylinders in
agreement with the IKEA product supplier. Also other forms of mechanical
devices can be used. Other types of undercuts can be made just by the
flexibility of the plastic material, consider if the mould design has allowance
for the movement of the plastic part when it is forced over the undercut.
4. DRAFT ANGLES
4.1. It is important that the draft angles are correct in consideration to the
preferred surface structure.
4.2. Also make sure that the part follows the moveable half when the mould is
opened. As stated earlier, we do not normally allow undercuts as a mean for
pulling the part to the right half.
6. RUNNER SYSTEM:
6.1. If a cold runner system is used it is important to assure that the waste is
minimized.
6.2. If a family mould is made it is important to consider if it should be possible
to mould the parts separately (for instance by rotating the sprue bushing).
6.3. The runner system must be balanced so the pressure and flow is equalized
in all the cavities. This applies both for cold- and hot runners.
6.4. If a three-plate system is used, the opening of the middle plate has to be
done with mechanical latches.
6.5. Only standard, well known complete hot runner systems will be approved.
Recommended hot runner system includes: Incoe, Moldmaster, Synventive,
Husky, Hasco, HRS, DME, Yudo, Thermoplay, Unitemp-Mould tip,
Thermoject, and Master flow.
6.6. The hot runner system shall be decided by the IKEA product supplier
6.7. Max one shot volume should be contained in the hot runner system, if
possible.
6.8. The hot runner supplier must supply locally spare parts, service and support
to the mould supplier and moulder, during the design of the mould and in
the testing of the approved mould.
6.9. The hot runner system should be designed for quick changes of colour/raw
material when applicable.
6.10. Hot runner ID-plate shall be attached on the operator side of the mould as
shown below:
Date: 2015-02-25
MOULD STANDARD Version no: 5:2
INJECTION MOULDING
7. VENTING:
7.1. Correct venting must be assured by the mould supplier.
7.2. A comparison to the mould filling analysis must be performed to optimize
the position of the venting.
8. TEMPERING:
8.1. A water diagram of the core- and cavity half shall be attached on the operator
side of the mould.
8.3. The pressure drop and flow needs to be measured as a reference for running
production with the mould to verify when the need of maintenance/cleaning of
the tempering channels are required.
• Cleaning of the tempering channels shall be done when the pressure drop
has increased and the flow decreased by 10%.
8.4. The temperatures for ”IN” and “OUT” of the tempering channels shall be
measured and documented during normal processing settings.
• IKEA request the temperature difference between “IN” and “OUT” should be
less than 6°C while running under stable conditions.
8.5. Plugs and baffles in the tempering channels should be manufactured of non-
corrosive and non-electrolytic materials.
8.6. All seals and o-rings should be made of VITON.
8.7. Leak testing of the tempering is required. This should be performed with
minimum 7 bar water pressure. No leakage is permitted.
9. EJECTION:
9.1. Consider the different types of ejectors (Cylindrical pins, sleeves, flat pin or
strippers)
• Always use standard components if possible.
9.2. The ejection system balance and required force must be considered to avoid
deformation and/or visual defects.
9.3. Withdrawal of the ejector plates must be done with return pins or another kind
of mechanical device.
9.4. Use a coupled rod to connect the ejector plates to the ejection movement on
the injection moulding machine.
9.5. If there is a risk of interference between ejector(s) and slider(s), a safety
protection system must be fully integrated (a micro switch signal the home
position of the ejector plates before closing the mould).
9.6. Guiding for ejector plates should be equipped with ball bushings or self-
lubricant bushings at all times.
9.7. If a two-step ejection is required, consider what moves first and how to
achieve this.
9.8. If a stripper plate is to be moved by the mould opening it should be done by
mechanical latches or hydraulic cylinder.
13. SAFETY:
13.1. All connections, such as tempering, hydraulic and electrical, must be
designed in a safe way so no harm can come to the operator while
working with the set-up of the mould.
Property of IKEA.
Article name: ex, Mammut chair, leg..
Mould number.
Mould producer.
H
Date YYYY-MM, ex 2014-06.
Mould weight XXXX kg ex, 1200kg.
Mould size W, L and H
Country of origin.
17. MAINTENANCE:
17.1. It is required that the mould supplier presents a maintenance program for
each mould specifying all necessary maintenance, maintenance frequency
and especially pointing out critical areas.
17.2. Complete files for all ingoing component is to be delivered with the mould
to secure the possibility to acquire spare parts.
17.3. This file shall also state the contact person at the mould supplier for
reference, in case of need of support occurs.
18. DOCUMENTATION:
18.1. Full documentation in English of the mould shall be issued by the mould
supplier in two copies.
• One complete file shall be sent to IKEA and another complete file
shall be sent with the mould.
18.2. The documentations shall (at least) contain the following:
• All drawings and 3-D files of all parts and components.
• Report from flow analysis.
Date: 2015-02-25
MOULD STANDARD Version no: 5:2
INJECTION MOULDING
Changes records:
2009/4/15 Edition 4.1: Adding 4.7 Hot runner ID card, modified 6.1 by adding water
diagram plate and taking away supplier name and number from the 12.1 marking
plate.
2013-02-26 Edition 5.0: Totally reworked
2013-05-30, point 5.4 gate rest is taken away, 6.5 spare parts & service locally is
added, 6.7 if possible is added, 9.8 hydraulic cylinder is added, 10.1 LKM is taken
away, 11.3 LKM is taken away, 16.3 complete new.
2013-06-09: 12,2 complete new.
2014-06-18: 1.2 acc to IKEA mould Assignment is added. 1.3 Complete new. 6.5
HRS added. 15.3 Article name Ex mammut chair,leg is added, Mould size W (mm), L
(mm), and H (mm) is added. 15.4 mould identification plate updated.
18.1 in English are added.