InjectionmoldingmachineSpecificationReva.doc.docx

NDBC SPECIFICATION FOR INJECTION MOLDING MACHINE PROCUREMENT

1.0 SCOPE

1.1 PURPOSE

This specification contains the requirements for the purchase of a new injection molding machine to produce injection molded parts internally.

1.2 APPLICABLE INFORMATION

The injection molding machine is to meet the following specs:

a) Condition: New and the current year’s model

b) Clamp Force: between 45 and 55 US ton

c) Shot size: between 1.2 and 3.3 in3 of a thermoplastic polyurethane (TPU) (i.e. Estane 58887 TPU (with a specific gravity of 1.20), IROGRAN® A 85 P 4394 UV, or IROGRAN® A 92 P 4637 UV DP)

d) Machine orientation: Vertical with sliding/shuttle/trolley table (not rotating table) or a stationary platen style.

e) Injection unit type: The manufacturer must specify the injection unit type: all-electric, hydraulic, or hybrid.

f) Clamping unit type: The manufacturer must specify the clamping unit type: all-electric, hydraulic, or hybrid.

g) Closed-loop barrel heating: Include at least three closed-loop barrel heating zones. The manufacturer must specify the number and location along the barrel of the closed-loop barrel heating zones.

h) Closed-loop control of metering, injection velocity, backpressure, holding pressure, and clamping force: The manufacture must specify the closed-loop accuracy and resolution of each. The manufacturer must specify the how many profile set points can be generated for each.

i) Parameter Monitoring: Include a system to monitor and export the following injection molding parameters: cushion volume, holding pressure, injection pressure, injection volume, cooling time, cycle time, holding time, barrel temperatures, and clamping force.

j) Additions: part ejector system using ejector pins, desiccant dryer to dry a 2 lb/hr of virgin thermoplastic polyurethane (i.e. Estane 58887 TPU, IROGRAN® A 85 P 4394 UV, or IROGRAN® A 92 P 4637 UV DP), and an auto-feed system. Additionally, if an external chiller is required for the injection molding machine, it must be include in the quote.

The manufacturer shall include the following services:

a) Machine installation: calibration of injection molding machine, balancing of the injection molding machine, and performing system checks.

b) Training with install: Initial basic training with machine install along with troubleshooting.

2.0 REQUIREMENTS

2.1 GENERAL

The details of the injection molding machine specs along with other key items are described below.

2.2 MACHINE REQUIREMENTS

2.2.1 CLAMP FORCE

The clamp force necessary for the parts we will be producing will be between 45 and 55 US tons. The machine clamp force will be closed-loop and allow the user to establish the clamp force set point and establish a tolerance range around the clamp force. The machine will have the ability to alert the user when the clamp force is outside of the tolerance range. Note: The manufacturer will specify the machine’s clamp force set point accuracy and set point resolution. The manufacturer will specify the clamping unit’s resolution of its clamping force tolerance range. The manufacturer will specify the type of clamping unit: servo electric or hydraulic.

2.2.2 SHOT VOLUME

The shot volume acceptable range for machine will be between 1.2 and 3.3 in3 of a thermoplastic polyurethane (i.e. Estane 58887 TPU (with a specific gravity of 1.20), IROGRAN® A 85 P 4394 UV, or IROGRAN® A 92 P 4637 UV DP). Note: The manufacturer will state the barrel capacity of the injection molding machine and the material used to size the barrel capacity of the machine.

2.2.3 MACHINE ORIENTATION

The machine will be new and the current year’s model. The machine will be vertical and will have either a sliding/shuttle/trolley table or a stationary platen. The machine will not have a rotary table.

2.2.4 MACHINE TYPE

The machine will be of a reciprocating-screw design. The machine will have a general purpose screw and tip design. The compression ratio of the screw will fall between 2:1 and 3:1. The general-purpose tip will have a 60° included angle, and a free-flow mechanism of either ball check or sliding ring type. The machine will include an anti-backflow valve. The machine will include a straight, open nozzle with a full internal taper.

2.2.5 CLOSED-LOOP BARREL HEATING

The machine will include at least three temperature zones maintained by closed-loop barrel heaters. These zones will have the ability to maintain a set point within a tolerance defined by the user. The resolution of the barrel heater tolerance should be less than or equal to ±5ºF. The machine will have the ability to alert the user when the temperature in one or more zones is outside of the tolerance. The manufacturer must specify the number and location along the barrel of the closed-loop barrel heating zones.

2.2.6 PARAMETER MONITORING

The machine will have the ability to monitor and export the following injection molding parameters: cushion volume, holding pressure, injection pressure, injection volume, cooling time, cycle time, holding time, barrel zone temperatures, and clamping force. The machine must have the ability to both store these parameters in the memory of the machine and export the parameters from the machine. Note: The manufacturer will state the uncertainty relative to full scale of each monitored parameter. The manufacturer will provide a list of molding parameters that can be monitored.

2.2.7 ADDITIONAL EQUIPMENT / MACHINE PARTS

The machine will have a hopper style desiccant dryer. An auto-feed system will be in place for safety purposes. The machine will have and ejector system that uses ejector pins. If an external chiller is required for the injection molding machine, it must be include in the quote. The manufacturer will provide a list of any additional external equipment, not listed in this specification that is required for the start-up and operation of the machine.

2.3 OTHER ITEMS / SERVICES

The following items are to be specified in the manufacturers quote:

a) The countries of origin of the parts, and machine. The country of origin of the corporate headquarters.

b) Warranty period

c) A statement about the serviceability of legacy (“older versions of”) injection molding machines. The statement will discuss the company’s policy regarding legacy injection molding machines including the typical lifespan of injection molding machine, the typical lifespan of a product line, and the typical period of time after the sale that the ability to purchase replacement parts is hindered.

d) Typical preventative maintenance schedule

e) Details on parts procurement

f) A list of distributors with contact information

g) Software description (required: software updates included in price)

h) The injection molding machine must be ANSI and OSHA compliant.

3.0 QUALITY ASSURANCE AND DELIVERABLES

3.1 QUALITY ASSURANCE

The machine will meet all requirements described in this spec and all deliverables promised by manufacturing company at time of contract/purchase awarded.

3.2 TESTIMONIAL QUALITY ASSURANCE

Prior to award the contractor shall provide NDBC with proof of quality assurance. Evidence can be provided in the form of previous contract, reports or testimonials.

3.3 DELIVERABLES

The following items shall be provided at time of contract award:

a) Machine and additional external equipment

b) Machine installation, initial training and troubleshooting

c) User’s manual

d) Document containing information on warranty and services offered

e) Emergency contact info in case of machine malfunction/problems