Die Specifics

Estimated Progressive Stations

  • Pierce

  • Profile

  • Pilot

  • Idle

  • Blank Out

  • Idle

  • Profile

  • Idle

  • Profile

  • Idle

  • Coin

  • Coin Terminal Ends

  • Form up

  • Idle

  • Separate Blank Size(T,W,P): 0.64*28*14

  • Die Size(L,W,SH): 500*400*400

  • Press Tonnage: 60

  • Die Weight(KG): 430

  • Strokes Per Minute: 120

    • Included:

    • Nitrogen Gas Springs

    • Bronze Bushing in Stripper Plate

    • Extra set of Cutting Details

Mold & Die Design Capabilities Applied/Processes

Mold Specifics

B&J International, LLC is a leading designer and fabricator of custom molds and dies for customers in a range of industries. In the project highlighted here, a customer in the electric industry contracted B&J to design and build a complete turnkey mold and die package for an electrical terminal and housing connector. The resulting parts would be used in an automotive electrical application. The process included meetings with the customer to ascertain part function, estimated annual usage, and quality expectations, as well as provide a cost estimate. A 1 out progressive die for the terminal and a 2 cavity shuttle mold were determined to be the most efficient tooling designs for the customer to meet their annual part requirements. Our supplier(s) then provided Die simulations as well as Mold Flow analysis utilizing advanced 3D software; once these were analyzed design began. Upon completion and customer approval of the designs the tool builds proceeded.

The tooling was produced offshore, with our local project managers closely monitoring the tool build. The customer was integrated into all phases of the design and manufacturing process, with detailed weekly progress reports. Off tool samples were sent to the customer, upon approval of the sample parts, the tools were shipped to the B&J facility where they were disassembled, inspected, cleaned, and reassembled before delivering to the customer. Final trials took place at the customer’s facility, with B&J personnel present.

The completed top mold base dimensions were 12.75" in length, 10.55" in width, and 3.34" in height; the bottom mold base was 12.75" in length, 10.55" in width, and 5.75" in height. The cold runner mold featured 400 stone polish on the hardened cavities and cores, subgates for a horizontal injection process, and was fabricated to fit an Autoejector 75 ton molding press. The Progressive die weighed 430KG, and utilized a 15 step progressive process, it is designed to run at 120 stokes per minute in production, with a press capacity requirement of 60 tons.

Primary: Progressive Metal Stamping Die

  • Cost Estimation (Includes Estimated: Die Size and Weight, Strip Width, Press Tonnage, Time to Off Tool Parts)

  • Pre-Design Kick-off Meeting at Customer’s facility

  • Die Simulation

  • Customer Strip Layout Approval

  • Customer Preliminary Design Approval

  • Project Management (Includes: Weekly Progress Reports, Digital Pictures highlighting tool build progression)

  • Sample Part Approval

  • Final Die Trial at Suppliers Facility (Our Personnel present)

  • Disassemble/Inspect/Clean/Reassemble (Domestic Facility)

  • Deliver to Customer

  • Final Trial at Customer Facility (Our Personnel present)

  • Customer Approval is required at each step of the project.

Capabilities Applied/Processes

  • Primary: Plastic Injection Mold (Terminals Inserted)

  • Cost Estimation (Includes Estimated: Die Size and Weight, Strip Width, Press Tonnage, Time to Off Tool Parts)

  • Pre-Design Kick-off Meeting at Customer’s facility

  • Mold Flow Analysis

  • Design

  • Project Management (Includes: Weekly Progress Reports, Digital Pictures highlighting tool build progression)

  • Deliver Off-Die Terminals to Mold supplier

  • Sample Part Approval

  • Final Mold Trial at Suppliers Facility (Our Personnel present)

  • Disassemble/Inspect/Clean/Reassemble (Domestic Facility)

  • Deliver to Customer

  • Final Trial at Customer Facility (Our Personnel present)

  • Customer Approval is required at each step of the project.

  • 2 cavity shuttle mold with 1 top and 2 bottom bases to fit an Autojector 75 ton molding press

  • Hardened cavities and cores

  • Cold runner with sub-gates (Horizontal injection)

  • Parting line locks

  • Guided and spring loaded ejector system

  • 400 stone polish on cavities and cores

  • Bottom mold base size 5.75 tall X 10.55 wide X 12.75 long

  • Top mold base 3.34 tall X 10.55 wide X 12.75 long

HIGHLIGHTS OF THIS MOLD & DIE DESIGN PROJECT

Dimensional Inspection, Gage Fit, Functionality Testing

Automotive Electrical

Indiana

Customer Specifications, 2D CAD Drawing Tolerancing

1 Out Progressive Die for an Electric Terminal 
2 Cavity Housing Connector Shuttle Mold

Estimated Progressive Stations

  • Pierce

  • Profile

  • Pilot

  • Idle

  • Blank Out

  • Idle

  • Profile

  • Idle

  • Profile

  • Idle

  • Coin

  • Coin Terminal Ends

  • Form up

  • Idle

  • Separate Blank Size(T,W,P): 0.64*28*14

  • Die Size(L,W,SH): 500*400*400

  • Press Tonnage: 60

  • Die Weight(KG): 430

  • Strokes Per Minute: 120

    • Included:

    • Nitrogen Gas Springs

    • Bronze Bushing in Stripper Plate

    • Extra set of Cutting Details

Mold & Die Design Capabilities Applied/Processes

Mold Specifics

In Process Testing/Inspection Performed

Industry for Use

Delivery Location

Standards Met

Product Name

OFFSHORE MOLD & DIE DESIGN & BUILD FOR AN ELECTRIC TERMINAL AND HOUSING CONNECTOR

Die Specifics

INTERNATIONAL TOOL PRICES, AMERICAN TOOL SUPPORT

B&J Enterprise Divisions