With over 35 years of injection molding
and mold building experience the R.S. Alberts Co. is one
of the leading pioneers in prototype injection molding.
Starting with hand made patterns and cast epoxy to construct
injection molds R.S. Alberts continues to build upon the
experience of its dedicated and talented staff. Over the
years new technology has emmerged that has enhanced the
prototype tooling process, from CAD to 3D product development
to Rapid Prototyping (LOM, SLA, SLA) to multi axis CNC machining.
Epoxy Tooling
This unique tooling process was the starting point for R.S.
Alberts Co. injection molding. (Tools are constructed using
an SLA master pattern, a parting line board and then a castable
epoxy is poured over the components). This creates the 1st
half of the mold. The second half is created in the same
manner. Prior to de-molding the cast epoxy is put through
a curing procedure in which the master pattern is usually
destroyed. With today’s technology the SLA process
is the most cost effective and quickest way to produce a
master pattern. Because of this the tolerance of the epoxy
tooling is driven by the SLA process. For areas within the
part design that might require a higher tolerance level
CNC machined metal inserts are used to achieve the best
results. Over the years The R.S. Alberts Co. has molded
many different injection molding materials such as polypropylene,
polyethylene, thermoplastic elastomers, ABS, polycarbonate,
PC/ABS blends, nylon, PVC and engineered resins including
long & short fiber glass filled, talc filled, flame
retardent and UV stabilizers. Tool life is directly dependent
upon part geometry and end use material. The very first
epoxy mold built at the R.S. Alberts Co. is still in use
today.
Aluminum Tooling
Building upon the years of epoxy tooling R.S. Alberts Co.
began to offer machined aluminum injection molds for prototype
and low volume injection molding in the early 2000’s.
Shortly after the 1st CNC machining center was brought in-house
it became apparent that some designs fit better into machined
aluminum molds versus cast epoxy molds. Additional CNC machining
centers and staff have been added. Utilizing the latest
in CAD/CAM software and mold grade aluminum R.S. Alberts
Co. is able to handle simple part geometry to complicated
multi piece designs.
Molding
With 8 injection molding machines, ranging from 25 Ton to
350 Ton, R.S Alberts Co. has the press size to meet most
injection molding requirements. In addition to having a
great history of running a multitude of different materials
The R.S Alberts Co. also offers the ability to mold in color.
Off the shelf colors are usually available at no additional
charges. If a color match is required R.S Alberts Co. has
the ability to obtain custom pre-blended materials for a
nominal fee. Over-mold applications are also available;
this is done by insert molding. The rigid sub-base is molded
first. Once all of those parts have been molded the tools
are switched out and the rigid part is inserted into the
over-mold tool. There have been advances in recent years
in the chemical make up of the over-mold materials that
will now allow us to over-mold without the need for some
type of mechanical undercut. Post molded secondary operations
include the addition of threaded insert, painting, EMI shielding,
pad printing and some assembly.
As the drive to market for our customers has changed over
the years, R.S. Alberts Co. has tried to react to those
changes as well. With a strong emphasis on customer service
and communication, R.S. Alberts Co. continues to be a leader
in the prototype injection molding industry.
