Solid Core PP Help 1

[RWS2015]

Hello,

I am new here and self employeed, but not an engineer. Don't beat me up
too bad. Part Details are at the bottom. I could not get picture
to upload. It's a "simple" part from sheet, but plastic
companies want me to buy FDA material 200 sheets + and
I want to run 5-10k parts max.

Have looked at having this injection molded
in several places. Two companies told me they
could run it and ended up costing me 6 months.
Both sides had indents from not cooling evenly,
and it needs to be flat on both sides.

I could write a book on failure regarding this part over
the last 6-8 months.


One company told me they could make it with MUD insert
and put water around it to cool evenly. Sent a picture with
dimensions, and got price for the mold and per part price. No
mold flow analysis given. Not sure if this is common or not. Feel
like another dead end.

Next option is a foreign company saying they make via cold
runner system. Not sure which way to go, but I do know I don't
want to waste more time.

Has to be solid core because new replacments are cut nearly in half
to replace old ones.

Is this part impossible? Am I wasting my time?

Solid core Disc
Black PP FDA approved (black required, material can change)
Diameter is 135mm (cannot change)
Thickness is 15mm (cannot change)
Center bore is 30mm +.250mm
M6 x 3 mounting holes on 80.1 B.C
Break sharp edges

Thanks to anyone who offers their expertise, I truly appreciate
it.

 

[TugboatEng]

It sounds like water jet cut from sheet can meet your dimension and time requirements. I'm guessing it doesn't meet your cost requirements.

 

[Pud]

If material group can be changed, I would try moulding in a styrenic material such as ABS or HIPS. Much leas shrinkage. PP has quite a large shrinkage as it's a semi-crystalline material. Styrenics are amorphous.

Of course, the tooling already made will make oversized parts.

Could also try 0.5 to 1% of sodium bicarbonate added to the raw material.Acts as a blowing agent.

Politicians like to panic, they need activity. It is their substitute for achievement.

 

[RWS2015]

Tugboat - Waterjet would work but to
buy 200 full fda pp 5/8” sheets is over $100,000

Pud - Very interesting & never brought up. The tooling has yet to be made. The two companies that said they could do it made a few samples in house that were awful. Could not believe they sent them to me. So never proceeded further, thank goodness.

Is ABS or HIPS black available in FDA?

 

[Pud]

There will be grades food approved.
Your moulder should be able to get one.

Politicians like to panic, they need activity. It is their substitute for achievement.