Injection Molded Product Solutions

Manufacturing Capabilities

Manufacturing services available include parts molding, secondary operations, hot stamping and complete final assembly.

Acorn-Gencon's Manufacturing Resources:

• A highly-qualified staff, running 28 injection molding presses.
• Presses range in size from 55 to 720-ton with state of the art hot stamping equipment and secondary work areas.
• Process Automation with Yushin 4-axis full servo-robots and Yushin pneumatic pickers.
• Insert molding and co-molding / over-molding
• Short and long runs
• Short lead-times
• Statistical Quality Control
• High Volume Production
• Robotic Automation
• IQMS enterprise software

Secondary operations:

• Sub-assembly to complete assembly
• Ultrasonic welding
• Hot stamping
• Retail packaging
• Part machining

Resin Mold Shrink Rate

All resins have different shrink rates depending on resin family, amorphous vs. crystalline materials, mold design, and also depending on processing conditions (cycle time and temperatures) as well as part design (shape and wall thickness). Resin also shrinks differently depending on the direction of flow, with (laminar) or against (transverse). The values below represent the laminar flow. The chart below displays the typical mold shrink rates for the most commonly used resins.

Printable Resin Mold Shrink Rate

Tooling

Our tooling department is fully staffed and committed to providing the best possible molds. The tooling department has an open door policy with engineering where all critical aspects of the mold are extensively discussed prior to the start of the project.

Acorn-Gencon provides parametric solid modeling and design capabilities. We use Solidworks software, AutoCAD and a variety a data types including IGES and DXF formats. We provide complete mold designs including assemblies, details and full 3-D solid models for CNC programming and electrode fabrication. Solid modeling gives us the option of creating direct SLA models for pre-manufacturing of tooling.

• Complete project management of both Asian and Domestic tool builds.
• Mainland China mold-making.
• Mold design.
• Mold maintenance programs.
• Mold sampling.
• Preventative maintenance program.

In addition to our mold design capabilities, we also provide part design recommendations to improve part integrity and mold cost reduction. We are committed to having a sound mold design and work closely with the customer to provide them with the best possible return on investment.

EnterpriseIQ's RealTime Production Management System

Acorn-Gencon Plastics, LLC uses the EnterpriseIQ's RealTime Production Management system to monitor and track all aspects of manufacturing in true real time.

All 28 of our injection molding work centers are linked to the RealTime Production Management server. As a result, cycle times, up-time, labor, scrap, work order quantities and job status can be monitored accurately and in true real time at any computer on our network. Production reports are generated automatically, eliminating the need for data entry and manual production reporting.

The RealTime system helps Acorn-Gencon optimize manufacturing processes and provide the best service and quality to its valued customers.

Download the RealTime Brochure here

Mold Classification

When you build a mold with Acorn-Gencon Plastics, you will have to make a decision on what mold classification you want us to design your mold to. Typically, a high volume (millions of parts per year), multi-cavity mold with a long product life expectation will be built to the highest classification. Classifications designate the number of cycles the mold will repeat before the customer can expect to pay for "wear and tear" repairs.