We have been manufacturing, high precision, high quality injection mould tooling for the packaging industries for over 20 years.
We can offer a fully comprehensive service encompassing:-
Project management
Mould tool design
Mould tool manufacture
Inspection
Mould testing and validation
Mould service and repair
Project Management
Professional Project Management is essential to ensure timely delivery and control of any project changes to meet customer requirements. At Ultratools Project Management is provided by time served engineers using industry standard software, techniques and methodologies. Customer consultation is an essential element of projects placed with us. With each project the manager will remain in regular contact, providing plans and reports until project completion.
Mould Tool Design
Our experienced design team specialise in high volume moulds for the packaging and medical industries. A high investment in leading edge design technology combined with a customer driven design philosophy gives us the ability to model and analyse moulds, components and tooling prior to manufacture.
Both 3D CAD (Unigraphics) and 2D CAD (Concerto / Autocad) are used for mould designs and detailed drawings. We can accept CAD data in most of the latest formats with few or no translation issues. On completion of a concept design the customer is invited to discuss the design parameters. Complex components are designed in 3D prior to conversion to manufacturing data through Delcam Powershape / Powermill. Component mould flow modelling is used to ensure that the cavity gating is positioned for optimal performance.
Inspection
Inspection occurs at all stages of mould manufacture. High investment in quantities of accurate inspection equipment and training of staff is driven by a philosophy for quality control. Customers receive reports on both steel and component inspection.
Equipment Listing:-
Brown & Sharpe Mistral CNC Co-ordinate Measuring Machine
3 - Brown & Sharpe Microval Co - ordinate
Measuring Machines
Baty R550 Optical Comparator
Baty R400XL Optical Profile Projector
Vision Lynx Stereo Microscope
Hahn & Kolb CNC Laser Marking Machine
Mould testing and validation
We have invested greatly in technology, training, machinery and ancillary equipment to test and validate manufactured moulds. We are unique in this sector of the industry with the ability to test on in-house Netstal, Husky & Battenfeld injection mould machines ranging from 80 to 150 tons locking force.
Equipment Listing:-
Husky S90 Injection Moulding Machine
Netstal Synergy 1500/460 Injection Moulding Machine
Netstal Synergy 800/230 Injection Moulding Machine
Battenfield 110 Injection Moulding Machine
Mould Service and Repair
We have dedicated staff for the repair and service of mould tools. Planned maintenance, customers are encouraged to consider our A/B/C maintenance procedure. This plan combines the production requirement of the customer with sensible/cost effective maintenance.
Moulds can be serviced to a pre-agreed schedule and fully detailed mould reports are submitted on completion. Moulds of up to 4 tonne can be handled in our repair/servicing section. We undertake moulds manufactured by other mould makers as well as our own manufactured moulds.
Multi cavity moulds for the ’Packaging‘ Industry.
The packaging industry demands high volume production runs. Our experience with this market has allowed runs of up to 1.5 million components per day to be produced. Typical types:-
Bump off ’Closure‘ moulds
Unscrewing ’Closure‘ moulds
Collapsible core ’Closure‘ moulds
Hot runner moulds
Semi hot runner moulds
Cold runner moulds
Moulds up to 64 cavity
Stack moulds for high volume disposable components
Generally for use in the packaging industry, stack moulds provide the highest output of components per production cycle. The mould maximizes the mould space available for a given size of moulding machine. Typical mould types;-
‘Dairy’ Closures
Tamper Evident Closures
Re-closure lids
Moulds of 48 cavity (2x24), 64 cavity (2x32)
and 96 cavity (2x48)
Multi Cavity moulds for the Medical & Pharmaceutical Industries
The medical sector demands the highest quality components. Our cavity tooling can provide accuracies of 0.01mm as required with consistency across all the impressions. Typical types;-
Medical device component moulds
Medical packaging component moulds
Contact Lens moulds
Moulds up to 64 cavity
Development moulds for new products
Development moulds are used to develop new components prior to committing to the manufacture of a production mould. This ensures that component features and geometry, gating positions and the choice of moulded material are optimized and tested for the subsequent high volume mould tooling.
Typical types;-
Medical device component moulds
Packaging moulds
Bump off closure moulds
Jar closures with collapsing cores