THE COMEBACK:
In 2008, the Manufacturer’s Directory in Michigan listed approximately 300 mold and die manufacturers, mostly concentrated around the Grand Rapids area. That number has plummeted, and today there are only about 150 of them. What caused this decline? A major factor was undoubtedly the recession, but some of these firms also fell victim to improvements across the industry as a whole. Advancements in the manufacturing process have created dies and molds that last longer, in turn driving demand down.
But the pendulum has swung back, and the remaining manufacturers are experiencing increased demand now that the supply of producers has dwindled. These firms are on constant missions to increase quality and efficiency to protect their positions and grow market share and Rex-Cut Mounted Points are helping them to do just that.
MOLD AND DIE MANUFACTURING - THE PROCESS:
Molds are typically used for smaller plastic parts. They consist of an upper and lower section, and runners through which the plastic is injected. These runners must have perfect finishes to prevent the plastic from sticking to high or low spots in the runner. Preparing the runner starts with a vitrified mounted point, followed by a resinoid abrasive mounted point to remove grinding marks, and a felt bob for the final finish. In some cases, a diamond abrasive may be used for more precise finishing.
Dies are typically used for larger steel parts, such as the hood or fender of an automobile. The dies are separated into an upper and lower section. A small dimple, known as a “boss” fits into a pin hole to lock these sections together. A mounted point is used to clean the bosses, followed by a specialized flat grinder that removes circular abrasive marks with a side-to-side motion.
WHY MOUNTED POINTS ARE SO IMPORTANT:
Both dies and molds are now produced with better finishes with either cutting tools or EDM machines. These production advancements help reduce the the amount of work needed to finish the parts and reduce some need for the vitrified points. Finishers now can produce a better finish quicker with the cotton fiber mounted points.
Rex-Cut Mounted Points are produced from cotton-fiber, compared to the traditional rubber mounted points used in other abrasives. The result is a more durable abrasive and a more consistent finish. The longer lifespan of Rex-Cut Mounted Points leads directly to lower abrasive replacement costs. But more importantly, the more consistent finish they provide reduces overall finishing time, and that drives down labor costs and overall production time.
In the past, a manufacturer might have employed 20-30 finishers in the mold or die production process. Manufacturing technique enhancements have driven that number down to an average of 6-10 employees today. This demonstrates the importance of efficiency in this industry—where labor costs average $40/hr per person. The Mounted Point step in the manufacturing process is a vital component that can either streamline operations or add costly delays. The importance of getting it right can’t be overstated.
With mounting pressure on mold and die manufacturers to do more with less, Rex-Cut Mounted Points alleviate a potential bottleneck in the finishing process to help manufacturers protect their competitive edges. It’s just the right formula to aid in insulating these organizations against uncertain economic times.
FIND THE RIGHT MOUNTED POINT FOR YOUR APPLICATION:
To find the right shape, bond, and grit for your application, follow our 5 step guide here.