Design of injection, die cast and vulcanised rubber moulds
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Mon - Fri 8am - 4pm
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(+48) 605 954 054

Welcome to

Pikform

We are a group of result oriented designers with 20+ year track record of providing design documentation for injection moulds, high-pressure die casting moulds for zinc and aluminium as well as vulcanised rubber moulds projects.
A wide range of additional services available allows us to comprehensively handle orders of any complexity.
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Injection Moulds
for thermoplastics
Efficient solutions for batch production
Vulcanising moulds
for rubber processing
Economy of production and ease of maintenance
HP die casting moulds
for casting of zinc and aluminium
Precision of shape and minimisation of machining
Production implementations
of plastic parts
From initial idea till final product
3D Printing
rapid prototyping
Pre-production verification of part concepts
Industrial design
of moulded parts
Ergonomics, style and technology
Injection mould adjustments
production optimisation
Adjustments and corrections of existing solutions

About us

Our goals

PIKFORM Design Office was established in 2005 with an aim of providing input documentation for tool shops which do not maintain their own design department. Today, we support both: the companies ordering mould documentation and, directly, the recipients of parts which are manufactured using tools we design. We supervise the complete process of product creation. Modern methods of mould kinematics designing (Solidworks 2020), injection process simulation (Moldex3D, MAGMASOFT) and in-depth supervision over 2D documentation allow us to realize projects with any degree of complexity.

Our core values:

■
Focus on the quality of parts manufactured using the moulds we design and technological suitability of the element for the injection process.
■
Efficiency of the production process carried out with our tools and reduction of production costs.
■
Technological feasibility of the mould's design in terms of tooling elements and assembly method, taking into account manufacturing capabilities of the tool shop and injection moulding plant.
Year of establishment

2005

Regular customers

30

All customers

83

Production optimisations

64

Number of own projects realised

950+

Workflow

We participate in all stages

Conceptual phase

Technological feasibility study

Tool design

Tool manufacturing

Injection tests

Tool modifications

Handover of documentation

The starting point for the design process of our moulds is an initial 3D model and a 2D drawing of the part which should be provided by the customer, along with a description of the desired functional features of the element. The more information we have, the more accurately we can estimate the level of complexity of work steps to be taken and select tool parameters ensuring maximal production performance.
Obtaining a part with the correct geometry, durability and high quality aesthetics requires following strict designing rules. Even the best design of a mould will not guarantee the desired properties of a part that does not meet the technological requirements for injection moulding. This is why we start our work with the customer at the early stage of detail's conceptual design, so that from the very beginning it is created with the selected method of production in mind.
Documentation development based on an adapted model of the part, moulding elements and mould mechanics. For complex cases it can be preceded by CAE analysis of the injection process taking into consideration the selected type of material and tool construction solution. In our projects we utilize standard components of leading European suppliers: MEUSBURGER, HASCO, PROPLASTICA and, where required, hot runner systems: INCOE, MOLDMASTER, ELWIK.
The precision of the moulding elements and the experience of the staff responsible for metalworking process is of vital importance for the quality of the tool and, consequently, the resulting part. During this stage we are in persistent contact with the mould maker. We cooperate both with workshops chosen by the customer, as well as with our long-term, proven partners. During the preparation of a project we pay special attention to the technological feasibility of all tool's elements.
Tests lead in production environment allow to judge the effectiveness of implemented solutions and give an insight into the areas where improvements can be made. Along with the properties of the part, mould kinematics and correct operation of all systems (thermostatic, hydraulic, hot runner etc.), the possibility of obtaining stable production parameters and possibly short production cycle times is also verified.
After a thorough analysis of the part obtained and taking into account all the remarks of injection molding plant employees, we implement modifications aimed at further increasing the effectiveness of the moulding process and perform possible corrections to the geometry of the core/cavity shapes. Once the changes are documented, they are forwarded to the tool shop, which adjusts the tool. Another production test verifies the results of the improvements. Depending on the complexity of the project, the cycle may repeat several times.
Once the customer has approved the part, we prepare a set of documentation containing a complete 3D model of the mould in the format required by the client, 2D documentation in the form of CAD files and, if requested by the customer, printed. Any optimisations to adapt the tool, introduced as a result of tests, are applied to the original versions of drawings and models. In addition, we provide schematics of the mould connections and recommendations for the operation of the tool.

Jak pracujemy?

Jesteśmy obecni na wszystkich etapach

Koncepcja detalu

Podstawą do rozpoczęcia prac związanych z procesem konstrukcji naszych form jest wstępny model 3D i rysunek płaski detalu dostarczony przez klienta, wraz z opisem założeń funkcjonalnych elementu. Im więcej informacji, tym dokładniej można oszacować stopień skomplikowania prac oraz dobrać parametry narzędzia zapewniające maksymalną ekonomię produkcji.

Analiza technologiczności

Uzyskanie detalu o prawidłowej geometrii, wytrzymałości i estetyce wymaga zachowania ściśle określonych zasad jego konstrukcji. Nawet najlepiej zaprojektowana forma nie zagwarantuje prawidłowych właściwości detalu, który nie spełnia wymagań technologiczności pod kątem wytwarzania metodą wtrysku. Z tego powodu pracę z klientem rozpoczynamy już na etapie fazy koncepcyjnej detalu, aby od początku powstawał on z myślą o wybranej metodzie wytwarzania.

Konstrukcja narzędzia

Opracowanie, na podstawie dostosowanego modelu detalu, elementów formujących i mechaniki formy. Dla skomplikowanych przypadków może być ono poprzedzone analizą CAE procesu wtrysku uwzględniającą wybrany typ tworzywa i rozwiązania konstrukcyjnego narzędzia. W projektach wykorzystujemy biblioteki normaliów wiodących europejskich dostawców: HASCO, MEUSBURGER, FCPK oraz, gdzie jest to wymagane, systemy gorącokanałowe ELWIK.

Wytworzenie narzędzia

Precyzja wykonania elementów formujących i doświadczenie pracowników odpowiedzialnych za obróbkę ślusarską ma istotne znaczenie dla jakości narzędzia, a co za tym idzie - uzyskiwanego detalu. Podczas tego etapu jesteśmy w stałym kontakcie z wykonawcą formy. Współpracujemy zarówno z warsztatami wskazanymi przez klienta, jak również z naszymi wieloletnimi, sprawdzonymi partnerami. Przygotowując projekty zwracamy szczególną uwagę na technologiczność wykonania wszystkich elementów narzędzia.

Próby
wtrysku

Testy narzędzia w warunkach produkcyjnych pozawalają ocenić efektywność przyjętych rozwiązań i umożliwiają ocenę obszarów, w których możliwe są usprawnienia. Poza właściwościami uzyskiwanego detalu, kinematyką formy i poprawnością działania wszelkich układów (termostatowania, hydraulicznego, gorącokanałowego itd.) sprawdzana jest również możliwość uzyskania stabilnych warunków produkcyjnych oraz możliwie krótkiego czasu cyklu produkcyjnego.

Wprowadzenie
modyfikacji

Po wnikliwej analizie uzyskanego detalu i uwag pracowników wtryskowni wprowadzamy modyfikacje mające na celu dalsze zwiększenie efektywności procesu wytwarzania oraz ewentualne korekcje geometrii detalu. Po przygotowaniu dokumentacji zmian, przekazywane są one do narzędziowni, która dostosowuje narzędzie. Ponowne przeprowadzenie próby produkcyjnej weryfikuje rezultaty usprawnień. W zależności od stopnia skomplikowania projektu cykl może powtórzyć się kilkukrotnie.

Przekazanie dokumentacji

Po zatwierdzeniu przez klienta detalu przygotowujemy zestaw dokumentacji zawierający kompletny model 3D formy w wymaganym przez użytkownika formacie, dokumentację płaską w postaci elektronicznej, oraz, na życzenie klienta, papierowej. Wszelkie optymalizacje mające na celu dostosowanie narzędzia, wprowadzone w rezultacie testów, naniesione są na pierwotne wersje rysunków i modeli. Dodatkowo dostarczamy schematy przyłączy formy oraz zalecenia dotyczące obsługi narzędzia.

Advantages

Continuous self-development and searching for new solutions allows us to meet the growing demands of our customers

The superior goal of a mould is the result of its action - the part

Engineering documentation of high quality

Easy-to-service tools

Solutions for injection moulding plants

Professional support for every aspect of the process

Flexibility of offered solutions - time and money

Our projects

Examples of special orders we have carried out for our customers

WORKPIECE PARAMETERS OPTIMISATION

Tool adjustment

Goal:
Reduce part weight and optimize production efficiency by modifying a HP die cast mold for aluminium (designed and manufactured by a competitive company)
Actions:
Relieving the weight of a workpiece by introducing ribbing, wall thickness correction in non-visible areas, applying industrial design to visible areas.
Result:
Part weight reduced by 30%
Production cycle time reduced by 20%

Increasing production efficiency

Tool adjustment

Goal:
Increase production efficiency and reduce part weight by adapting forming nests and tool functional sections
Actions:
Normalisation of wall thickness, introduction of ribbing in thermal junction areas, increased efficiency of the thermostatic system for cavities and forming cores
Result:
Improved workpiece surface quality
Eliminated problems associated with casting defects
Reduced part weight from 2.4kg to 1.9kg

Contact us

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Our work

Packagings
Home & office
Automation
Automotive
Lighting
Cosmetics & Medical
Construction acc.
Furniture acc.
Other
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Questions and answers

The following list presents the most frequently asked questions of our new clients
The valuation of the mould design is free of charge. This also applies to the cost estimation of additional services that may be required during the order's execution.

How much does a mould design quote cost?

The cost of each mould project is estimated individually. Due to the varied complexity of elements produced by injection molding or pressure casting, it is impossible to determine the price range without an analysis of the specific case. In order to obtain a quotation, please contact us by phone or fill in the form on our website, enclosing a 3D model and the necessary information described below.

How much does a mould design project cost?

For each case the timerange and cost of an injection mould project preparation is estimated individually after initial conversation with the customer and determining the required scope of work. To evaluate the cost of service it is required to analyze a 3D model and/or 2D documentation of the element or a  pecimen part along with other information described below.

How long does the project cost estimation take?

The deadline for submitting the preliminary documentation is determined at the time of project valuation. Apart from the complexity of the element and the scope of work required, it is significantly influenced by the proper course of cooperation with the design department responsible for the conceptual design of the part.

How long does it take to prepare a mould design?

Quotations are prepared on the basis of information obtained from the customer. The necessary data is:
  • a 3D model (e.g. Solidworks, Parasolid, IGES);
  • a 2D drawing with manufacturing tolerances of the target part specified;
  • exact name of the material that will be used to manufacture the part or a description of the part's properties - we will help with choosing the appropriate type of material;
  • information about the product's functional destinaniton and aesthetic parameters (defining surfaces visible to the end-user, their type of texture, etc.);
  • estimated production volume;
There is also a possibility to design a mould on the basis of a supplied sample part.

What information is required to valuate the project?

The process of plastics processing and metal HP die casting features a number of factors that have a significant impact on the result. In order to ensure repetitiveness of product properties, stability of its geometrical and aesthetic parameters, it is necessary to follow the design rules specific for plastic elements, i.e. to maintain appropriate geometrical conditions, sometimes taking into account the anisotropic properties of the material and phenomena related to the crosslinking process, as well as solutions allowing for moulding of the workpiece and its subsequent removal from the mould.

What is the purpose of the part's technological adjustments?

Many times we have provided services of existing solutions adjustments provided by competitive companies. Depending on the needs, optimizations have been focused on improving the properties of parts obtained, introducing structural changes in the elements or improving the manufacturing performance. While performing this type of tasks we consult with process technologists, whose experience allows to reach maximum production efficiency of the tool.

Adjustments of existing moulds -  it possible?

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Contact

Postal address:

PIKFORM Paweł Kiełbus

46g Wyścigowa St.

26-600 Radom

Mobile:

(+48) 605 954 054

Email:

pawel@pikform.pl

NIP:

959-010-04-56

REGON:

140049609

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