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Specification Sheet for Moulds: ENQUIRY ORDER

Component Name: Plastic material:
Component No.: Colour:
Serial No.: No. of cavities:
Machine type \ Screw diameter:
Date: Approved by:
Supplier approval of conformity signature :

RUNNER AND GATE:

a) Cold runner Runner should not exceed 25% of the shot weight
b) Central hot bush with cold runner - Supplier: Runner should not exceed 25% of the shot weight
c) Partial hot runner - Supplier: No. of hot bushes Runner should not exceed 25% of the shot weight
d) Complete hot runner - Supplier:
e) Tunnel gate COOLING:
f) Edge gate a) With cooled cores
g) Sprue bush flat seating. Diameter of hole to be > Ø 4mm b) With cooled inserts
h) Sprue bush spherical seating R c) With cooled plates

CONNECTIONS:
a) Connector for hot runner power/signal cable - Type:
No. of pins Numbering system to match with cavity identification
Type of thermocouple to be Fe-Cu Ni
b) Mould temperature sensor hole on both halves. Refer to drawing number M01
c) Cooling nipples to connect to the machine: Hasco type Z81/9/8 x 0.75 or Z81/9/10 x 1 and to be recessed.
For 'O' rings it is mandatory that you use standard Viton 'O' rings purchased only from Hasco or Meusburger.
For cooling nipples recess refer to drawing
number M02. If the recess is not possible than provide spacers to protect the connection nipples from being damaged. Inlets to be
marked 'IN' (IN 1, 2, etc) , and outlets to be marked 'OUT' (OUT 1, 2, etc)
d) Push rod. Refer to drawing number

MATERIAL: 1.1730 1.2312 1.2767 1.2343 Orvar Stavax Calmax UNIMAX 1.2085 Hardened Surface
Supreme ESR Uddeholm Uddelholm (Ramax S) HRC Coated
Uddeholm Uddeholm

Mould plates
Clamping plates
Intermediate plates
Ejector plate
Inserts
Use different steels with different hardness of approximately 2-4 HRC on surfaces sliding with each other. Specify surface coating:
Unimax to be heat treated at 54-56 HRC, harden at 1000-1010 x2 temps at 525°C

MISCELLANEOUS:
a) Cavities in jaws to be manufactured out of separate inserts.
b) Pressure Blocks to be one solid piece from the mould plate.
c) Hydraulic cylinders to be equipped with limit sensors.
d) Cavity identification (numbers or letters).
e) Engraving to be made on separate inserts.
f) Pneumatic coupling for activating hotrunner needle valve. Type __________________________________
g) Locating rings to be on both halves and according to the dimensions shown. (Refer to drawing number M13).
h) 2K moulds are to be equipped with return springs on ejector plate.
i) Insert moulded tools that are going to be used on turntable IMM are to be equipped with return springs on ejector plate.
j) Safety bar/latch to be provided for the ejector plate to eliminate possible damage on the inserts and ejectors during transport.
(where applicable).
k) Locating units to be provided (where applicable).
l) Limit switch to be provided for the ejector plate to be mounted on the top side of the mould. Type: HASCOZ140/1
Refer to drawing number M11.

Retention period: Production + 1 yr

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Retention method: Hard copy
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Screws to hold stationary side inserts/complete mould plate to be accessed from the front of the mould; not to damage the hot runner
m)
system during dismantling.

n) Cycle time not to exceed

Life time of tool to be M Shots M Parts
o) The Hasco Z53 Standard Sprue Puller Insert to be used or similar.
Do not hesitate to contact us if there are any queries regarding this information.
GENERAL REQUIREMENTS:
1 Complete original tool drawings (hard copies) with the Methode Electronics Malta Ltd. format to be available with the moulds.
2 3D CAD data of tool models in STEP format and 2D drawings in DXF format are to be available on a CD with the moulds.
3 3D mould assembly model to be available on a CD with the moulds and must conform with the mould supplied.
4 CAD data/drawings for EDM electrodes to be included on CD.
5 All requested CAD data is to be available also on our FTP site prior to delivery of mould.
6 2D CAD data for the drawings to be on individual sheets. (Refer to Quality of CAD Data Guidelines).
7 Drawings to be in 1st angle projection.
8 All dimensions to be in mm.
9 Methode Parts List (BOM) format MB57 to be submitted with the CAD data in EXCEL format.
10 Any information/notes on the drawings to be available in English.
11 Drawings and 3D models of the tool layout should be submitted prior the design review meeting.
Design review should be documented and compiled on our standard format MD75 by supplier and approved by Methode Electronics Malta Ltd.
12
together with the tool design layout for release prior to manufacture.
13 Design reviews should also include diagrams or sketches showing split lines, ejectors, injection point location, special areas/finishes, etc.
14 Critical dimensions that should be left with metal safe should be agreed during the design review. Fine tuning to be done in-house

Although Methode Electronics Malta Ltd. approves the tool design layout/design review, it is still the full responsibility of the supplier to resolve any
15
issues or defects both on part and on tool until both are fully released.

16 Any plate having cooling channels to be manufactured out of 1.2085 (Ramax S) regardless of previous instructions
17 Insulating plates to be on both halves.
18 Tool base to be standard from Hasco/Meusburger/DME
19 Clamping plates to be bigger than the tool base to clamp directly with cap head screws from the front of the machine platens.
Refer to drawing number M04.

Transport bar to be provided with an M12/ M16 or M20 hole for the eye bolt according to the weight of tool and to be engraved
20 with Methode's tool serial number whilst also painted in colour according to our Colour Coding Diagram located in our ZIP file name ' Order
Tooling Package ' provided at Kick off.

21 Ejector plate to be guided with bushes and pins

All waterlines have to be connected with fixed or flexible tubes (Hasco Z856; Z805 and/or SMC THxxx/KF). Each mould half to have only one inlet
22
and one outlet. Depending on mould size.
All parts subject to wear like inserts, cores must be designed as individual and replaceable single part in order to reduce maintenance cost to the
23
lowest level.
24 Electrodes to be available with the moulds.
25 Mould release agent is not permitted.
26 Welding is not permitted.
Progress update to be supplied every fortnight starting from release of order (every 2 weeks) and every week for the last four weeks.
27
Manufacturing process sheet to be used. (refer to - Tool manufacturing process check sheet.xls)
28 3D CAD data in STEP format and 2D drawings in DXF format of the hot runner system are to be available together with the JOB No.
28 MEM Tool Tag which is supplied by Methode is to be affixed to the mould
29 Tag which is supplied by the hot runner manufacturer is to be affixed to the mould.
A wiring diagram for the hot runner system to be engraved on a separate template and affixed on the nozzle side facing the operator side and
30
nozzle tips to be numbered accordingly. (Refer to supplied drawing - Hot Runner Specs M07).
31 Any discrepancies between the model and the associated drawing are to be discussed with Methode Electronics Malta Ltd.
32 Whenever possible sampling is to be carried out on Arburg Injection Machines.

Moldflow analysis is mandatory and to be submitted together with the Design Review Meeting Minutes compiled on Methode standard format form
MD 75. So as the analysis to be conforming with Methode specifications as a minimum requirement it should consist of the following studies : Fill
33
Time / Pressure at V/P switchover / Temperature at Flow Front / Clamp Force : XY Plot / Volumetric Shrinkage / Air Traps / Sink Marks /
Definition all effects . These together with an MFR file generated on same studies.

Retention period: Production + 1 yr

MD 68ak- Spec Sheet
Retention method: Hard copy
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No warpage and sink marks are allowed on the finished component particularly in areas of significant importance such as A surfaces and
34 functional features. The subcontractor shall perform at his expense whatever type of research and verifications necessary to ascertain the part
drg/design does not contribute to a tool design allowing for such conditions.

35 Samples to be submitted according to contractual agreement.

36 All plates more than 15kg should have threaded holes for handling. (refer to - Examples.xls tool handling).
Guide strips for sliding jaw tools should be located and grooves to be implemented for grease as shown on sketch (refer to - Examples,xls guide
37
strip).
38 All cores and inserts have to be marked as shown. (refer to Examples.xls marking).

A full measurement report with a marked up drawing to be carried out with first initial samples and whenever there is a dimensional change or
correction on the tool, in the latter case this report is to be carried out only on the affected dimensions. For any case it is imperative that the same
39
actual samples measured are to be properly labelled and clearly marked and sent to Methode accompanied with same Measurement Report
together with the usual requested 60 shots sample size.

Process setting chart MW169 should be filled accordingly and submitted with first initial samples, when conducting the OEE exercise and
40
whenever there is a change in parameters. Refer to matrix for ideal parameters MW169.

Packing exercise should be conducted and information compiled in our MW169 Packing Graph Form in order to establish the holding pressures.
41
This form to be submitted with the first initial samples and whenever there is a change in parameters.

Tool should be tried out for a minimum run of 8 hours unless instructed otherwise. Information compiled in our MW69 Overall Equipment
42
Effectiveness For Moulds. This exercise should be made when parts are dimensionally released.

GENERAL REQUIREMENTS con't:

43 Parts to be injected in a fully automated process and manual interventions by the operators are not allowed
A full shot sampled at start/stop and at one hour intervals should be checked visually and dimensionally. The CC dimensions generated from these
44
measurements to be submitted in a report accompanied with the measured parts clearly identified for each hour.
45 A complete shot including runner to be available with every submission of parts.
Any interventions following the first off samples should be recorded on the attached electronic tool card under column titled Remarks. A copy
46
should be sent whenever comments are added to the sheet.
This document is to be endorsed by supplier signature and returned to requisitioner before tool dispatch to assure that all the above mentioned
47
requirements were adhered and observed.
It is forbidden to use any type of Friction Pullers for having pre movements of stripper plates etc. like for instance the HASCO Friction Pullers type
48
Z 172 . To use other alternatives like Round latches or other standard Latches etc.

49 All moulds are to be installed with a HASCO Cycle Counter type - A 5730 / 47.5 x 38 x 24.5 and to be fixed preferably on operator side.

REMARKS:

Retention period: Production + 1 yr

MD 68ak- Spec Sheet
Retention method: Hard copy
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Sub contracted Tools Checklist Date:

DESIGN REVIEW TOOL EVALUATION

General Mould and Part Details
1 Supplier
2 Project Name / Switch No.
3 Component Name
4 Part no.
5 Tool Serial no.
6 No. of cavities

Runner, Gating and Cooling

Not in Not
In Order Remarks / Supplier Feedback
Order Applicable
7 Type of runner
8 Correct dimension of runner
9 Type of gate
10 Correct dimension of gate
11 Flat sprue bush seating

12 Runner should not exceed 25% of the shot weight

13 Cooled cores
14 Cooled inserts
15 Cooled plates

Connections
Not in Not
In Order Remarks / Supplier Feedback
Order Applicable
Hot runner power/signal connector. Correct no. of
16
pins?

17 Temp. Sensor holes on both halves - Drw M01.

Cooling nipples (IN 1, 2. etc/OUT 1, 2, etc) to be

18
recessed, Hasco - Drw M02.

Use standard Viton 'O' Rings purchased only from

19 Hasco or Meusburger. Refer to drawing number
MO2 for cooling nipples recess.

20 Push rod according to Drw.

Material

Available Not Available Remarks

21 Type of steel to be used on toolbase and cavities

22 Material Certificate

23 Certificate of heat treatment (including hardness values)

• To carry out a hardness test to verify cavities/cores. I.O N.I.O

SMED / Quick Change Over

Are the below processes influencing quick change overs? Yes No Remarks /Actions

24 Connection and disconnection of flow supply lines.

25 Connection and disconnection of hot runner supply.

26 Clamping of tool on injection press.

Retention period: Production + 1yr

MD 68ak - Tool Checklist
Retention method: Hard copy
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Is pre-heating of mould possible to be done prior to setting up on

27
injection press.

Retention period: Production + 1yr

MD 68ak - Tool Checklist
Retention method: Hard copy
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Others
Not in Not
In Order Remarks
Order Applicable
Cavities in jaws to be manufactured out of separate
28
inserts.

Pressure Blocks to be one solid piece from the

29
mould plate.

Hydraulic cylinders to be equipped with limit

30
sensors.

31 Cavity identification (numbers or letters)

32 Engraving to be made on separate inserts.

Pneumatic coupling for activating hot runner needle

33
valve. Type _________

34 Insulating plates to be on both halves.

Locating rings to be on both halves and according

35
to the dimensions shown (Drw M13).

2K moulds are to be equipped with return springs

36
on ejector plate.

Insert moulded tools that are going to be used on

37 turntable IMM are to be equipped with return
springs on ejector plate.
Safety bar/latch to be provided for the ejector plate
38 to eliminate possible damage on the inserts and
ejectors during transport (where applicable).

39 Locating units to be provided (where applicable).

Limit switch to be provided for the ejector plate to
40 be mounted on the top side of the mould (Drw
M11).
Screws to hold stationary side inserts/complete
mould plate to be accessed from the front of the
41
mould; not to damage the hot runner system during
dismantling.

Tool base to be standard from Hasco /

42
Meusburger / DME.

Clamping plates to be bigger than tool base to

43 clamp directly with cap head screws from front of
machine platens (Drw M04).
Transport bar to be provided with an M12/ M16 or
44 M20 hole for the eye bolt according to the weight of
tool and be engraved with mould serial number.

45 Ejector plate to be guided with bushes and pins.

The Hasco Z53 Standard Sprue Puller Insert to be

46
used or similar.

Complete original tool drawings (hard copies) with

47 the Methode Electronics Malta Ltd. format to be
available with the moulds.

3D CAD data of tool models in STEP format and 2D

48
drawings in DXF format saved to a CD.

3D mould assembly model on CD and conforms to

49
the mould supplied.

CAD data/drawings for EDM electrodes to be

50
included on CD.

All requested CAD data is to be available also on

51
our FTP site prior to delivery of mould.

2D CAD data for the drawings to be on individual

52
sheets. (Refer to Quality of CAD Data Guidelines).

All waterlines have to be connected with fixed or

flexible tubes (Hasco Z856; Z805 and/or SMC
53
THxxx/KF). Each mould half to have only one inlet
and one outlet. Depending on mould size.

Retention period: Production + 1yr

MD 68ak - Tool Checklist
Retention method: Hard copy
 Page 7 of 7

54 Electrodes to be available with the moulds.

3D CAD data in STEP format and 2D drawings in

55 DXF format of the hot runner system are to be
available together with the JOB No.

Tag which is supplied by the hot runner

56
manufacturer is to be affixed to the mould.

A wiring diagram for the hot runner system to be

engraved on a separate template and affixed on the
57 nozzle side facing the operator side and nozzle tips
to be numbered accordingly. (Refer to supplied
drawing - Hot Runner Specs M07).
All plates more than 15kg should have threaded
58 holes for handling. (refer to - Examples.xls tool
handling).
Guide strips for sliding jaw tools should be located
and grooves to be implemented for grease as
59
shown on sketch (refer to - Examples .xls guide
strip).
All cores and inserts have to be marked as shown.
60
(refer to Examples.xls marking).

Methode Parts List (BOM) format MB57 to be

61
submited with the CAD data in EXCEL format.

Design review should be documented and compiled

on our standard format MD75 by supplier and
62 approved by Methode Electronics Malta Ltd.
together with the tool design layout for release prior
to manufacture.
Any plate having cooling channels to be
63 manufactured out of 1.2085 (Ramax S) regardless
of previous instructions
All parts subject to wear like inserts, cores must be
designed as individual and replaceable single part
64
in order to reduce maintenance cost to the lowest
level.
MEM Tool Tag which is supplied by Methode is to
65
be affixed to the mould

Moldflow analysis is mandatory and moldflow

66
reports are required prior to tool design stage

It is forbidden to use any type of Friction Pullers for

having pre movements of stripper plates etc. like for
67 instance the HASCO Friction Pullers type Z 172 .
To use other alternatives like Round latches or
other standard Latches etc.
All moulds are to be installed with a HASCO Cycle
68 Counter type - A 5730 / 47.5 x 38 x 24.5 and to be
fixed preferably on operator side.
Additional Remarks /
Comments:

Reviewed by:

Retention period: Production + 1yr

MD 68ak - Tool Checklist
Retention method: Hard copy