An apparatus, system, and method of forming a mold insert for an injection molding operation, comprising: providing a design of an injection mold part; analyzing, by a predictive model, the design to determine a conformal cooling arrangement for a mold insert for forming the injection mold part; and forming the mold insert including the conformal cooling arrangement.

Techniques are described for injection molding. When material inside a cavity of a tool is solidified into a molded part, the tool imparts a finished surface onto the part, including sidewalls with a zero or low-draft angle. To allow separation from the cavity without using sleeves or sliders, the cavity is widened, just prior to the part being ejected. The tool is made from metal with a high coefficient of thermal expansion, so the size of the cavity can be manipulated using temperature control. Heat applied to an outer portion of the metal surrounding the cavity pulls the metal away from the part creating an air gap within the cavity. Carefully applied cooling to an inner portion of the metal blocks the heat and keeps the surface temperature under control, which preserves the finished surface on the part. When the air gap allows, the part releases from the cavity with the finished surface intact.

Techniques are described for injection molding. When material inside a cavity of a tool is solidified into a molded part, the tool imparts a finished surface onto the part, including sidewalls with a zero or low-draft angle. To allow separation from the cavity without using sleeves or sliders, the cavity is widened, just prior to the part being ejected. The tool is made from metal with a high coefficient of thermal expansion, so the size of the cavity can be manipulated using temperature control. Heat applied to an outer portion of the metal surrounding the cavity pulls the metal away from the part creating an air gap within the cavity. Carefully applied cooling to an inner portion of the metal blocks the heat and keeps the surface temperature under control, which preserves the finished surface on the part. When the air gap allows, the part releases from the cavity with the finished surface intact.

A thermal management system that provides metal mold surface temperature control using cyclic process thermodynamics to enhance plastic material flow and curing conditions making it possible to produce resin rich molded plastic surfaces without micro cracks or fissures to which contaminant particles can adhere or to which dirt can attach.

A display cover can include a rectangular body having opposing outer and inner surfaces and an edge that connects the outer and inner surfaces. A central region, widthwise edge regions, and lengthwise edge regions can each define a portion of the outer and inner surfaces, and the edge regions each can extend from the central region to define a portion of the edge. The central region can be planar such that a plane lies between the outer and inner surfaces throughout the central region. Each of the widthwise edge regions can curve away from the central region such that a line that is tangent to the outer surface at the edge region is substantially perpendicular to the plane of the central region. The body's average thickness can be less than or equal to 0.5 mm, and the body can comprise at least a majority, by weight, of a polymeric material.

A display cover can include a rectangular body having opposing outer and inner surfaces and an edge that connects the outer and inner surfaces. A central region, widthwise edge regions, and lengthwise edge regions can each define a portion of the outer and inner surfaces, and the edge regions each can extend from the central region to define a portion of the edge. The central region can be planar such that a plane lies between the outer and inner surfaces throughout the central region. Each of the widthwise edge regions can curve away from the central region such that a line that is tangent to the outer surface at the edge region is substantially perpendicular to the plane of the central region. The body's average thickness can be less than or equal to 0.5 mm, and the body can comprise at least a majority, by weight, of a polymeric material.

Methods for preparing thermoplastic automotive appliques include applying heat from an auxiliary heater to a tool cavity of a forming tool. The auxiliary heater is activated for a period of time until a temperature of the heated tool cavity is heated to less than or equal to about a melting temperature of the thermoplastic. The heated tool cavity is filled with the thermoplastic, and a cooling fluid is pulsed through the forming tool. The thermoplastic applique is then removed, and the supply of cooling fluid is turned off.

Methods for preparing thermoplastic automotive appliques include applying heat from an auxiliary heater to a tool cavity of a forming tool. The auxiliary heater is activated for a period of time until a temperature of the heated tool cavity is heated to less than or equal to about a melting temperature of the thermoplastic. The heated tool cavity is filled with the thermoplastic, and a cooling fluid is pulsed through the forming tool. The thermoplastic applique is then removed, and the supply of cooling fluid is turned off.

There is provided a cooling mold for cooling a resin preform that has a gate portion protruding outward from a center of a bottom portion, in which an accommodating space that accommodates the preform is formed in the cooling mold, a bottom region facing the bottom portion of the preform in the accommodating space has a shape following the bottom portion of the preform, and an air sucking hole for sucking air is formed in the bottom region at a position shifted from the center of the bottom portion of the preform.

There is provided a cooling mold for cooling a resin preform that has a gate portion protruding outward from a center of a bottom portion, in which an accommodating space that accommodates the preform is formed in the cooling mold, a bottom region facing the bottom portion of the preform in the accommodating space has a shape following the bottom portion of the preform, and an air sucking hole for sucking air is formed in the bottom region at a position shifted from the center of the bottom portion of the preform.