Class 101 mold is built for extremely high production. It is made with the highest quality materials, and, therefore, is the most expensive class of mold. Class 101 mold must go through 1 million or more cycles, and the base must reach a minimum hardness of 28 R/C. Molding surfaces must be at least 48 R/C. Cavities, cores and slide cores must include temperature control measure whenever possible. Cooling efficiency is affected by corrosion as the mold ages; so non-corrosive materials are recommended. A guided ejection system must be used.
Capabilities
Engineering & Tooling Experience To Meet Your Plastic Molding Needs
Our engineering process includes reviewing product design, performance requirements, compliance tolerances, tooling needs, program timing, training…
“The Total Solution Provider”
Capabilities:
- In House Engineering & Design
- Product Development
- Design for Manufacturability
- Material Selection
- Rapid Prototyping
- FDM
- SLA
- Castings
- Prototype Tooling
- Production Tooling
- Tool Design
- Tool Building (USA & China)
- Full ISIR Submissions
- Machining
- Metal Castings
- Metal Stampings
- Full Production Facility
- In House Engineering & Design
- 30 to 1,500 tons
- Over Molding
- Insert Molding
- Value Added Services
- Pad Printing
- Heat Staking
- Ultrasonic Welding
- Assembly
- Packaging
- Test Fixturing
- Automated Assembly
- Painting
- Plating
- Shielding
- Warehousing
- Distribution
Materials:
ABS, Acetal, Acrylic, Nylons, Polycarbonate, Polyester PBT/PET, Polyethylene, Polypropylene, Polystyrene, Polyurethane Flexible/Rigid, Polysulfide, LCP, Thermoplastic Elastomers TPE/TPO,
Filled materials, Custom compounding, and more.
File Formats:
Pro-E, Unigraphics, AutoCAD, SolidWorks, DFX, IGS, STL, and more.
Quality:
ISO 9001, FDA Certified, 21 CFR Part 820 Quality System Regulation Certified, GMP, ITAR.
Contact:
Todd Holloway
President
Richard C. Remmy
Sales & Tooling & Engineering Manager
Injection Molding That Gives You A Competitive Edge
Total customer satisfaction is our mission. Our molding capabilities cater to both short and long-term production runs. High volumes range upward to several million per job order. From raw material through packaging and delivery, product and process are scrutinized for continuous improvement. Process efficiency is a cohesive force: Technology, cooperation, and teamwork unite to deliver peak value, production efficiency, and faster-to-market availability.
- ISO 9001 Certified
- Horizontal Injection Molding from 40- to 1500 ton Clamp Capacity
- Precision and Repeatability to Achieve Critical Dimensional Requirements
Foreign Tooling
OFF – SHORE TOOLING PRICES WITH DOMESTIC ASSURANCES
We have partners that use SLS, SLA, DMLS & FDM depending on your requirements, we can utilize which …
We have partnered with many facilities located in the Dongguan Province Close to Hong Kong International Airport and Seaport. For over 25 years we have been building Quality Molds for our internal molding operation as well as building molds for other molders across the country.
All molds come with a minimum of 250K to 1MM shot warrantees backed up and supported by our in house tooling department located in our USA Manufacturing Facility in Michigan City, Indiana
Our Tooling Capabilities range from 80 Ton to 1,500 Ton . All molds are are ungrated, cleaned, and re-sampled in our manufacturing facility to ensure Quality and proper Mold prior to final delivery or in house production.
3D Printing Services
We have partners that use SLS, SLA, DMLS & FDM depending on your requirements, we can utilize which …
Upload a cad to start ( STEP, STP, IGES, IGS, SLDPRT, 3DM, STL, OJB, or X_T) Please advise the Quantity you will need , functionality of part and any information you feel will be helpful We will quote from one of our 3D printing service’s that best meets your needs .
Domestic Mold Building
MOLD DESIGN AND MOLD BUILDING FOR LONGEVITY AND PERFORMANCE
MOLD DESIGN AND MOLD BUILDING FOR LONGEVITY AND PERFORMANCE
A well designed mold is the main factor for a successful part. This complex and precise process determines part manufacturability and lifecycle costs and takes into account the key components of mold design while adhering to a parts’ unique specifications
Proper mold design and mold building will help reduce cost , increase quality and optimize performance . We at Lighthouse use the latest CAD technology and software to create a mold design that is built to customer needs ani budget . (SPI STANDARDS MOLD CLASS 5 options ) We offer (DFM sample ) , including mold flow analysis to evaluate all mold designs and parts prior to development .
If your Injection mold needs require, we at Lighthouse can offer the following
- High Cavitation molds
- Automatic unscrewing molds
- Hot Manifold molds
- Stack molds
- Over molds
- Insert molds
- Prototype molds
- MUD molds
- Family molds
MOLD TRIALS AND QUALIFICATION
We offer weekly progress reports with pictures leading up to the mold trial . Mold trial includes videos, and ( FAI) first article Inspection for part dimensions are then review for accuracy
MOLD TRANFER PROGRAMS
Lighthouse has successfully managed numerous mold transfer programs , from one to many molds. We will inspect and evaluate the mold molds , and proceed to get them up and in production quickly and cost effectively
MOLD MAINTENCE PROGRAMS
Plastic Injection molds are an important asset and regular maintenance is important for longevity of the mold and the quality of the part it makes . We customize our program to include major and minor maintenance and repairs .
OVERSEAS MOLD BUILDING AND TOOLING
Lighthouse has over 25 years experience building plastic injection molds in China , We have partnered with many tooling facility in Shenzhen, Guangdong Province & Taizhou, Zhejiang Province Overseas mold building offers tremendous cost savings . Molds are built and sampled in China . T-1 parts are sent to our manufacturing facility and to customer for approval . After mold or molds arrive in the USA, we will then preform the Final Production Part Approval Process per customer requirements .
In house Tool Fabrication
We offer price, service, quality, and flexibility on both short and long-term production runs, operating out of with over 35,000 sq. ft. of manufacturing space
We have experience in medical injection molding, Class VI-compliant, high-performance materials and international trade. We understand that many healthcare product manufacturers do not want production handled out side of the U.S. for a number of reasons–Rigid FDA regulations, material contamination, the exposure of their intellectual property are all concerns of many healthcare companies.
SPI SPE Classification
Class 101 Mold
Class 102 Mold
Class 102 mold is a medium- to high-production mold. It is good for abrasive materials and/or parts that require a close tolerance. This mold is of high quality. Class 102 mold must go through fewer than 1 million cycles, and the base must reach a minimum hardness of 28 R/C. Like Class 101 molding surfaces, Class 102 molding surfaces must be at least 48 R/C. Temperature control measures are used in all cavities, cores and slide cores whenever possible. Guided ejection, slide wear plates, corrosive resistance and plated cavities may not be required.
Class 103 Mold
Class 103 mold is a medium-production mold. It is a popular mold and is in a medium price range. It must go through fewer than 500,000 cycles, and the mold base must have a hardness of at least eight R/C. The cores and cavity must meet a minimum hardness of 28 R/C. Any extra factors, such as guided ejection and corrosive resistant materials, are optional.
Class 104 Mold
Class 104 mold is is a low-production mold. It is used for limited production, primarily with non-abrasive materials. It has a low to moderate price range. Class 104 mold must go through fewer than 100,000 cycles. The mold base can be mild steel or aluminum. Cavities can be made of aluminum, mild steel or any other material that is agreed upon by the manufacturer and the customer.
Class 105 Mold
Class 105 mold is for use only in prototyping. The mold is constructed as inexpensively as possible in a very limited amount. Class 105 mold should not exceed 500 cycles. This mold may be made of cast metal, epoxy or any other material offering sufficient strength for prototyping purposes.
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