One of the primary keys to success in mold manufacture is proper construction and machining of the master model which is used to create the mold. The mold is a mirror image of the master and the finished part reflects the surface of the mold. BCT concentrates a great amount of effort on the master models to insure enhancement in every stage subsequently.

BCT is able to solve any unusual and complicated geometry customers may have by using a computer surface model to mill full-size master models with the promise of precision, less cost, and faster turnaround time.

CNC Milling Process

• Design part using CAD surface design program
  
• Output geometry to a file in a format compatible with CNC CAM software
  
• Read geometry file into CAM program
  
• Adapt geometry to meet the needs of CAM software
  
• Define cutter tool paths over the surfaces using CAM software
  
• Mill tooling block
• Apply tooling paste
• Mill cured tooling paste into final shape
  
• Preparation for use

Traditionally when machining solid tooling block masters, the material has a tendency to stress relieve while cutting. Additional areas of concern include warping in flange areas or where the material becomes thin. In order to prevent deformation, BCT over-mills foam block, then applies tooling paste, and mills the final shape of the master. This process forms a strong shell preventing any movement. When masters are rigid, molds are better and more precise parts are then molded.

Because of experience and training, BCT engineers are capable in the foresight of possible problems. Suggestions are given in the decision-making process such as what type of material should be used, whether to build a male or female mold, and how the mold should be designed.