AVAILABLE MACHINES (Mold Shop)
CNC MILLING
CNC ELECTRO EROSION

ELECTRO EROSION
TURNING MACHINES

MILLING MACHINES
DRILLING

Automotive industry
Exterior trim parts
Interior trim parts
Air nozzles / channels
Rear reflex reflectors
License plate lamps
Indoor Lighting Devices / Reading Lights
Cable ducts
Engine assembly trim parts
IP / Dashboard trim parts
Sun visor trim parts
Door trim parts
Center console arm rest, trim parts
White goods industry
Chiller group
Door Shelves
Plastic Drawers
Trim Panels
Painted / Patterned / Coated Trim parts
Laundry group
Door seals
Front panel, enclosure body
Outer door covers
Detergent group parts
For undercut areas, jeagle, lifter, plate puller, double hit, plate retarder etc. molds
Plastic injection molds on metal (overmould)
2K injection molds (PA66 GF30, plastic injection over TPE)
Conformal cooling molds
Reflective molds for lighting products
Rear taillight assembly molds
A) Plastic injection mold

These are the molds in which the most plastic types are produced according to the purpose of use. The plastic raw material melted in the injection furnace is injected into the mold with high pressure. It takes the shape of the plastic mold that cools in the mold. The duration of this process is short enough to be measured in seconds. With this method, plastic parts in very precise dimensions can be produced. Inappropriate products can be recycled and shaped again.

B) Thermoset mold

Unlike injection molds in such molds, thermoset and composite plastics are baked under high temperature and pressure to take the shape of the mold. During production, overflow burrs are formed, these burrs are cleaned by applying processes such as cabinetry, sanding and vibration. Plastics shaped by this method cannot be recycled again, just as baked bread cannot be turned into flour again.
Sample products: Bakelite electrical materials, Melamine plates, Ashtrays Etc.

C) Thermoforming (Vacuum) Molds

In this molding method, the plate made of plastics in the thermoplastic group is heated and sucked on the mold by vacuum, allowing the product to take its form.

D) Blow Molds

The best example of these products are bottles. While the molten plastic pipe flows from the furnace. It is trapped between the mold and inflated in the mold by giving compressed air at a point. It takes the shape of the plastic mold that cools inside the mold.

E) Extrusion mold

The plastic melted in the extrusion furnace is continuously poured through the mold and cooled by air or water at the exit of the mold. Window door profiles, hoses, cables, etc. are produced by this method.

F) Rotation Technology

ROTATION TECHNOLOGY
Rotation technology is a technology suitable for producing complex and monolithic forms. Mold costs injection, blow molding etc. It is the only plastic production technology to be used for low production rates, as it is more suitable than technologies. In this technology, molds are made in 2 different ways as sheet and aluminum.

Hair Rotation Molds

2.5 - 3 mm. thick HRP sheet metal, are molds made by shaping by hand workmanship. They are especially preferred for large products (such as water tanks). Its advantages are low mold costs. However, precise mold measurements and perfect surface quality cannot be obtained since they are mostly handcrafted and their assemblies are by welding sheet metal. It is correct to make sheet metal molds for products whose dimensions are not precise and that do not require good surface quality.
[name # cnc336x280]

PROCESSING OF PLASTICS WITH ROTATION TECHNIQUE

The movement of objects by following different rotation paths connected to a center is called rotation (loop). The rotation technique is called the shaping of plastics by using the centrifugal force obtained by rotating them at high speed and in different axes. A large number of plastic tools and equipment are produced with rotation molding technology, which is the production method used for shaping plastic raw materials.
The main purpose of shaping plastic raw materials using the rotation technique is to make it possible to produce materials that are complex in shape or very large in size.
Rotation allows the parts that can be added to the finished product to be added to the part during production. (Insert parts, flanges) Since the coloring agent is included in the raw material, there is no need to paint the resulting product. Plastic products produced by rotation are easier and cheaper to transport because they are lighter than metal and fiberglass. The products are durable, durable and resistant to corrosion.

ROTATION MOLDING

Molds that give the appropriate plastic raw material the shape prepared according to the desired product space for the production of large-sized plastic products (playgrounds, bins, etc.) are called plastic rotation molds.

PLASTIC ROTATION MOLD ELEMENTS
Generally in a rotation mold; metal spacer, flanges, bolts, vented

rma pipes are indispensable elements of a mold.
Apart from these, there are parts that allow rotation molds to be connected to crane chains. In addition, metal clamps were added to the mold in order to safely connect the parts of the rotation molds, which are manufactured in two parts, to each other.

MATERIALS USED IN THE MANUFACTURING OF ROTATION MOLDS
In the production of molds that shape plastic raw materials in production with rotation technique, mostly DKP sheet material is used. Since the rotation mold does not work under high pressure, the mold is produced from thin-thickness sheet material. Molds can also be produced from aluminum materials in some cases.

PRODUCT SPACE AND FEATURES IN ROTATION MOLDS
The product cavity is the name of the section where the plastic raw material inside the mold prepared according to the size and shape of the product to be manufactured is placed.

The product cavity in the mold is produced by considering the shrinkage shares according to the dimensions of the plastic products. Since the product will be manufactured by placing plastic raw material in the product cavity, the surface is desired to be bright and smooth. In addition, metal wire brushes and sanders are used to clean the rough roughness on the surface of the product cavity. If the mold is made of aluminum material, the inner surface is given a shine by chrome plating. According to the product to be obtained, the product gap surface can also be polished by coating with sandblasting technique. In this technique, micron-sized sand grains are sprayed on the surface to be polished. Another surface polishing technique used is the coating of the surface with tefllon. In this technique, the surface is coated with a glossy Teflon material with micron thickness.

ADVANTAGES AND DISADVANTAGES OF ROTATION TECHNIQUE

The main purpose of shaping plastic raw materials using the rotation technique is to make it possible to produce materials that are complex in shape or very large in size.
Rotation allows the parts that can be added to the finished product to be added to the part during production. (Insert parts, flanges…) Since the coloring agent is included in the raw material, there is no need to paint the resulting product. Plastic products produced by rotation are easier to transport and cheaper because they are lighter than metal and fiberglass. The products are durable, durable and resistant to corrosion.
Other advantages of rotation technology are explained below.
Short production time
Double skin possibility
Ability to fill foam
Economic feature in low production quantities, as in high production quantities
Raw material selection according to the application
Scarce amount of scrap
The need for sharp corners may be counted.
The factors that make it difficult to use the technique of forming the plastic with the Rotation technique, whose superior aspects are mentioned above, are explained below.

Relatively low production speed, compared to blow molding, hundreds, thousands, tens of thousands of products are produced annually in rotational production. When it comes to millions of production a year, injection or inflation should be considered.
· Using a limited variety of raw materials, powder LLDPE is the most ideal material for rotation molding, but it is not suitable for every design. Unfortunately the moldable polymer is limited; Thus, what we can do with PE is also limited.
The need for a large-scale workshop environment, as well as the need for very large areas for loading and storage operations.
· Its production with the rotation technique has caused it to remain as a production branch where hard investments and few factories are opened in the plastic forming sector.
The first striking feature of the machines that make the production of the method of shaping plastics by rotation is their size. The rotation machine size is also getting larger so that products with large dimensions can be easily rotated inside the molds.

Rotation machines can be examined in two main sections;
· Furnace section; It is the name of the section where the plastic product mold is placed together with the raw material, where the cooking process takes place at a certain time interval in order for the raw material to take the correct shape at the appropriate temperature.
Car partition; It is the mechanism that carries out the movement of molds that produce rotation into and out of the furnace.

Characteristics of a rotation machine are explained below.
Machine working system;
· Heating system
Transmission Parts (Dc Engine)
Drive system
Door Controls (Pneumatic)
Conformity to Need in the Machine
Below is a rotary machine that can manufacture 3 arms.

The machine has the following features.
Loading station
Cooking station heated with diesel, fuel-oil or natural gas
· Air cooling station.
· Mold size is maximum 100cm.
Suitable for polyethylene and PVC manufacturing.
In the manufacture of PVC balls, 78 pieces of 9cm molds or 44 pieces of 13cm molds can be mounted on each arm. Ball molds of different weights can be connected at the same time.

UNITS OF ROTATIONAL MOLDING MACHINE
Rotas, which performs the rotational molding process

We can examine the Router with the following units.
Combustion Chamber and Heating Cabinet: There is 1 burner that ensures combustion and 1 fund to distribute the heat homogeneously to the oven. Combustion is carried out in a special boiler. This heat is transferred from the combustion chamber to the heating cabin with the help of fans and thus the temperature of the mold increases and the purpose is achieved.

Mold Change Station: Molds are positioned as U and straight arm. It is attached to the arms on the motorized cars. The molds are connected manually by the operator according to the order and demand.

Cooling Station: The mold is taken out of the heating station and sent to the cooling station, where the mold is connected to the mold changing station area, when necessary, by using different rotation ways on the arms connected to the car, and the cooling process is performed as free cooling by using air or water.

Mold Clamping Unit: After the rotation molds are manufactured, they are fixed to the rotation arms connected to the trolley by the operator using fasteners (bolts and nuts).

Machine Heating Unit: For heating, it will work with an automatic control sensor that works with LPG (Liquid Petroleum Gas) and accordingly works with 1 fan. During the heating phase, the mold gradually rotates in 2 axial paths. This is called rotation in two axes. The heat melts the material put into the mold as much as the weight of the product to be produced, allowing it to take the shape of the inner surface of the mold.

It is necessary to make different settings of the machines that produce with the rotation technique before the production starts, while the production continues and at the end of the production, like other machines that process plastic raw materials. In addition, attention should be paid to the changing values ​​of the settings according to the changing product features and a setting information bank should be created.

The settings made in the rotation machine; We can examine the rotation speed, the amount of raw material, the turning time, the temperature values, the adjustment of the cooling time.

ADJUSTING THE ROTATION SPEED
Rotation takes place in two axes (x-y) in rotation machines. There are two important factors affecting the rotation speed of the rotation mold. These;
The shape, size and material properties of the manufactured product:
The rotation speed of the mold changes by paying attention to the product features. The rotational speed of a large-sized tank and a small-sized garbage truck are not the same due to differences in their dimensions.
Rotational speed ratios are also related to the physical properties of the mold attached to the machine; Attention should be paid to features such as the density of the indentations-protrusions, the mobility of the raw material in the mold, the wall thickness of the product to be obtained, and most importantly, where and how much thickness is required.

Station location of the mold during the manufacturing phase:
There are two different stations. The rotational speed of the mold in the combustion chamber and the heating cabinet station is different from the rotational speed of the mold in the cooling station. In the heating station, the rotation speed setting should be faster than in the cooling station, since the raw material in the mold is heated and it is desired to be plastered on the inner surface of the mold. Adjustment of return time at both stations, with the help of automatic time adjuster panels can be adjusted electronically or manually.

SETTING THE RETURN TIME
The rotation time of the rotation mold is decided by considering the factors affecting the rotation speed of the mold. Variables such as the size of the mold, the wall thickness of the product and the type of raw material used, the name of the station where the mold is turning affect the rotation time of the mold. The adjacent picture shows a rotating rotation die in the cooling station.
ADJUSTING THE AMOUNT OF RAW MATERIAL
The amount of raw material is related to the thickness of the requested material, it means the thickness of the material. When calculating the amount of raw material, when we calculate the surface area of ​​the product (cm2) and multiply it by the density of the raw material and the desired wall thickness (cm2), we determine how much raw material will be used.

ADJUSTMENT OF HEAT VALUES
Adjusting the temperature values ​​for molds is related to the working technique of the heating system used in the rotation bench, and we can classify them as follows.

Natural gas
LPG
Diesel
Like electrical energy

The heating system takes place through a burner for the first three systems, while in the other and not preferred method, the molds are heated in the furnace by using electrical energy and resistances. set in degrees