@@Armuotas The plastic is "injected" into the mold, sometimes flowing "around" other parts placed in the mold before hand, like in the case of this valve. "Exjected" sounds like all the plastic just spilled everywhere.
I just spent 15 minutes totally engrossed in the production of an extremely cheap ball valve. I’m glad you’ve chosen to use your powers for good and not evil Old Tony.
Didn't expected to see a content creator consuming the content of another content creator, almost as if the youtubers ware like.. like me.. watching together shows we make... Like we are brothers... Srry, I get star struck :3
Hi, Tony, I have worked in injection molding for the last 22 years. You are really close on most everything. The mandrel is called a core and that would be on the cavity half. You would load seal-ball-seal and the core pin on the core half would come up and preload the insert stack of the ball and seals as the mold closes. Around the periphery of the core side core pin will be another witness line that's the ejector sleeve. This is an ejector pin but tubular. This process is overmolding they call it insert overmolding. We do this with an aluminum hub in a steering wheel. The wrinkling opposite the gate is known as jetting. They just blasted the shot in too fast on the first stage of the shot before a flow front had time to form. Keep up the fantastic work you are one of my favorate CZcamsrs!
I learned a wee bit about injection molding when I worked for a plastics fabricating company. One cool thing I learned is that there is no "heater" involved in melting the plastic. The drive screw forces the plastic into an ever smaller space formed by the screw threads and diameter until it reaches the aperture and then it's in a liquid (or semi-liquid state).
There most definately is heaters, usually three band heaters, referred to as "zones" to keep the temperature stable and the plastic molten. Sure the shearing induces heat to the plastic, but you can't rely on that alone.
Well, maybe in different applications or materials? These were never discussed in the courses I took nor with the owner of the injection company I worked with. Now maybe technology has changed, we're talking 25 years ago......
Depends mainly on the type of part and production cycle (as parts per unit of time) of the mold. You have heaters on the injection machine and in some molds (depending on the part geometry, the time of each cycle, etc) you have hot runners (nozzles with heaters) .
It's my understanding that the heater bands are there to maintain the temperature of the material in the barrel when the screw is not in play in fact a lot of our machines drop power to heater bands until the machine times out in order to save power that's normally on our ppf dedicated machines because the melting temp is lower then abs or pcabs also some molds have hot runners to maintain even heat threw out the mold and aid in the smooth flow of material
A rod through one of the holes in his bench down to his rotary weld table underneath? I have no clue I don't even feel qualified to watch his videos let alone comment
@@jakemrcool that was my first thought but it would be such an intricate touch for it to skip along with his speaking... maybe yiure right I shouldn't put any level of detail past him
Jeff Petersen I would live to see you make some videos and teach a sparky like me. I have a hobby lathe and I'm loving it but precision past tenths is amazing
Jeff Petersen . As a custom molder who regularly had to deal with someone else's mistakes I appreciate a good tool and die maker and getting them involved on the front end of a project. A great way to loose money is chasing the cheapest tool price.
Ave did the same video and I just watched it again before this, but it’s not in my history. Thank you guys so much because I thought I had just lost my mind.
the mold actually isnt a perfect negative, it also takes into account shrinking due to the cooling of the plastic which can be quite a lot. Which is also why mold making is a real art
Especially before Moldflow and similar software. Even after the mold is designed and fabricated you can change the part size slightly by changing the process conditions (but that tends to compromise cycle time).
The thicker bottom of the valve is probably intentional as well. I hypothesize that it would increase flow along the bottom where the plastic is injected versus the rest of the part allowing control of how the weld line forms at the top
I just watched this for a second time after and extended time, even though I recalled it very well, but this time with a focus on the writing, presentation, and production.
This is really genius Sir. And I like the way you presented it, it was very funny informative and you provided right information at right time. This is the best 15 min of Tech video I have ever seen. I have not just earned how it is made but the process of how you approached it was brilliant. You made it so easy to understand. Thank you
The E and D are called cavity ID . That way if there is a defect you can tell which cavity did it. Most tools make more then one part at a time. We have molds that make up to 36 parts at once. Oh yea I've been a tool maker for 30 years. You did an excellent video explaining basic molding and yes you are right about the over molding.
I love showing these videos to my two kids! Thank you! Much better than a “how it’s made” video. A real person, with a real brain, in their garage, doing stuff. ❤️
"Genius is an infinite capacity for taking pains." Thomas Carlyle - and that is how I view your work Tony. And, of course the same goes for the patient developer of the ball valve you dissected. This is quality video!
Coming from a design engineering background, it's incredibly refreshing to listen to someone else go through a similar analytical process as myself when presented with something that is a small work of genius ^_^ Very entertaining! I enjoyed the mental exercise of predicting your points before you said em! I'd love to see more like this in future =]
Wow! I've used hundreds of these pvc ball valves and it never occurred to me what a wonder of industrial technology they are. I think a 1/2" valve at the big box stores around here would be like $1.85. Unbelievable.
"Patient died, but the operation was a success." Love your commentary and how you explain things in a funny way. Keep up the good work. Greetings from Germany.
This video is... genius. I find the topic of injection molding really interesting, I never figured so much effort goes into minimizing cost. Also, I like these 'kind of deep dive' videos.
I understand injection molding, like just about everything these days, is a incredibly complicated subject, that's why I wrote "kind of deep dive". What I wanted to say was I like this explainey type of video.
I knew some of this having worked on an injection molding line one summer but your explanation was much better. A few things I learned that summer: One some machines run much hotter than others, polystyrene takes only a little heat, PVC a bit more, and Polycarbonate is scary to mold. Two when a mold is blocked they like to crank up the heat even more, the foremen got localized 2nd and 3rd degree burns all the time when the molds would "clear" themselves. And three, all parts are made of either "virgin plastic" or regrind, Four flash and sprue always need to be trimmed from the parts, always. This is the job the noobs get and hated. You can also mold in thread inserts and all sorts of other interesting things.
tony is more funny than 98% of the channels that are out there to make you laugh. and that last 2% are just on par with him. i get more laughs watching this than actual blatant comedy skit/oriented shows/channels. Tony, your sense of humor hits home with me. i love it. that and im 26 and learning that i dont know shit about anything. i thought since i was a mechanic working on cars i knew a thing or two. but watching your channel has taught me i'm still a baby bird of the mechanical world. and by baby bird i mean an egg, but maybe the beak has made it through the shell, just kinda poking out. but every time it pokes out it says shit like "im a mechanic" so people think i know what i'm doing
I work in a factory doing injection molding for shoes, specifically rubber soles and plastic heels. Despite most of the products we make need quite a high precision, we still use aluminium alloys molds that get banged really easy, but also the work time of those products are sometimes over the 3 minutes total between injection and cooling, also they all require quite some calculation to prevent mismatching once the rubber/plastic shrink after cooling, cause it can mean a size 10 sole could become a size 8!
2 notes... Betting the "mandrel" is part of the whole mold. One seat and the ball are stuck to one side of the tool, and the other seat is on the other side of the tool, and when it comes together, the center seals on the ball itself. Part the second, the thicker on the bottom than the top is probably intentional so the plastic flows more reliably to the far side of the mold from the injection point.
czcams.com/video/LfiRGJYjgMs/video.html That's what it look is going on here, except there is a mandrel attached to the ball for the handle to be attached later.
Most injection molding content on CZcams relates to simple obvious molds, like the axe-head packaging. Thank you for showing something more complex and amazing.
A truly amazing teacher is a rare gift, and I’m extremely grateful you’ve gifted us all with these lessons. I have an intense curiosity about how things are made, and your videos are the best satiety I’ve found. Thank you!
There was a video on the jerry can, where they enumerated all the ingenious design decisions made for such a simple looking tool. I loved it because I feel like brilliant engineering lives among us, every day, unnoticed. I like videos like this that are, "let's take a few dollars of plastic and look at why this is absolutely brilliant."
My father was a mechanical engineer, and when I was very young I remember how amazed he was by the precision of the mouldings in the first Lego set he bought me - that would have been around 1963 or so, when the first of the modern style bricks were released. Up to then you either had Meccano nuts and bolts, or your construction toy either wouldn't go together properly or fell apart - well, there were some plastic construction toys that worked OK, but not by press-fits of perfect force. You are right, it is a miracle of modern engineering.
The truly amazing thing about LEGO is the absolute quality standard that has been maintained for over 50 years. Take one of the early LEGO pieces and it will snap onto a current production part just as crisply as two made 10 seconds ago. As to the shape of the bricks and their method of locking together LEGO the idea had been used before on products not up to the same quality level as LEGO. Interestingly there are free 3D printing files to make adaptor blocks to enable LEGO to be used with other building set styles. www.fastcompany.com/3054837/build-with-lego-knex-and-8-other-toys-at-once-with-this-free-universal-adapter-set So if you've got a 3D printer and kids (or grandkids) who do stuff with LEGO or any of the other brands it can open another world of possibilities.
I’ve been working in a plumbing warehouse the last 3 months and I see so much of this stuff everyday and I never really thought this deep into something so simple. Genius
the only genius wasnt only the people who designed the valve but also the person who made and presented this video. a really excellent vid. so many thanks
I laughed, I loved, I learned.... Well done Tony! (Seriously, this was one of my favorites. I hope you do more "how it was made" style vids in the future.)
The drill housing was likely made using multiple shot injection molding. The whole part being made in one tool. The red plastic would be shot first then then the tool would have inserts that would back off, just enough to make room for the black plastic, then the second shot would be injected. Check out multi shot injection molds, iv seen up to 4 shot molds, 4 separate plastics in one tool.
i’ve used many of this valves over the years and not once stopped to appreciate how these are made. i love knowing how things work, how things come together and such. i have a new found appreciation for pvc ball valves and whom ever designed these little marvels
A former Mechanical engineer and soon to be retired dentist I am always impressed with your video's. An incredible amount of work goes into them, the humour is priceless and the insight and intelligence you display never fails to amaze and entertain me. This injection moulded valve video was GREAT, I've seen the valve but never had the inquiring mind to figure out how they were manufactured. So thanks for the info AND the entertainment!
Robert Leitch . One way to do it is with 2 injection units and a rotating platen on one half of the tool. Shoot the plastic part rotate half the mold close on another half of the tool having space for the rubber over molded grip and shoot it again with the other injection unit... or a third unit..
A buddy of mine has a big scrap yard and gets the old injection molding machines from a few big name manufacturers in our area. They are absolutely huge despite the often small parts they make. I helped cut one up last summer that made parts the size of a popcan and the machine itself was 25 feet long and weighed about 20 - 25 tons!
Seal, bullet proof, got a good laugh out of me. Very good videos, keep up the great work. We need the younger generations to get educated in manufacturing and trades.
That is what I was thinking also, I was looking for a comment to see if anybody else caught it and agreed with me. Not saying this confirms we are right.
I worked in the metal diecasting field for many years in my youth. That all came back to me watching this video. We also had some parts that had inserts that we put into the die so as to become one part when cast. And the part of the die that held the inserts were called cores. Sometimes the part required cores not inline perpendicular to the parting line and those required a moving core that would be put into place using its own hydraulic cylinder after the diet closed.
The two-story tall injection molding machines I used to work on and build molds for injected rubber and plastics at up to 5000 psi. The "shot" cylinder hydraulics worked at up to 3000 psi. I learned very quickly that even 1/2" grade 8 bolts and hardened steel dowel pins used in assembly of the mold cores and mandrels didn't stand a chance holding pieces in place against the forces of the incoming material "shot". Typically gate placements and runner lengths and size had to balance opposing material pressures and cancel out these forces, or parts, no matter how stout, would shift and part wall thickness would be inconsistent. I made my first complex mold (for a large rubber bellows similar in shape to a car's CV joint boot) bread and butter style, and the core was a series of sharp edged "flying saucer" shaped discs held together by a long 1" dia. bolt thru the center of about 12 stacked discs, varying diameters, 0.500" thick each (like a stack of hotcakes). The outer mold halves were made the same way, but the stacks were held together by a series of shorter bolts on different overlapping centers, and final facing of the mating surfaces was done last, so the outer mold halves essentially became permanent assemblies. The first trial shot was a disaster. The injected rubber penetrated between the discs and forced the discs apart against the closed ends of the mold, stretching the 1" high tensile steel center bolt and locking the mold closed with the core and part trapped inside. It took nearly 30 tons of hydraulic press, hammer and chisel, and pry bars to separate the mold halves, and the part came out in shredded tatters. I tried to increase the clamping force between the discs, but even with as many high strength 1/2" and 3/8" bolts added on peripheral bolt circles I could fit in there, the mold core expanded and locked up every time. I then re-thought the way the flow of the material shot caused it to wedged between the discs as the shot entered the mold. To keep it from forcing its way between the discs, I finally got it to work by adding 0.050" outside radius fillets in the "vee" where the discs came together. The incoming material flow was thus re-directed to flow across the parting line instead of wedging into it. As a bonus, it also eliminated nearly all of the witness mark and flash. I then applied for and received customer approval to add matching radii to the outer pleats of the bellows as well, after I demonstrated how much improved the product looked and functioned. Mold making luck and black magic, I guess...
Please don't take this wrong. I do so enjoy an "intelligent" smart ass. Your informed dry wit makes me chuckle so often I must remember to make regular visits to the bathroom less I have an embarrassing accident at my age.
No matter how simple the video This Old Tony always makes it interesting. Always looking forward to the next video from the best CZcams channel going GW
I always get a kick out of your videos, well written, illustrated and presented. I love the subtle references, well placed most times, to other awesome CZcamsrs, keep up the fantastical work.
Used to work in the mold making and die casting business up around Erie, PA years ago. Go laid off and never went back. Loved the work, miss it in some ways. Can live vicariously watching your vids. Thanks.
He didn't say it was the number of times it could be recycled. He said it was the number of times you'll get to use it before you lose it or run over it with your car.
The injection-moulded parts on Dyson vacuum cleaners are fascinating to look at - the metallic-looking additives allow you to see the flow and weld lines quite well.
Some molds are very simple and some are very complex indeed. Bottles - inject resin, rotate, cogitate, blow air in and then Freon. Viola bottle. Then there are those with holes and 4 dimensions... I think some of the fancy ones are Engine blocks and maybe calculators... Thank for the dissection!
Noone: Absolutely noone: CZcams Recommendations: here watch this video on injection molding of a PVC valve from 2 years ago Me, who knows nothing about manufacturing and has never watched a video about anything like this at all: *watches entire thing and enjoys it*
I buy these for my garden irrigation projects where I live in Thailand, except here they are blue PVC. Maybe has something to do with Elvis. Maybe not. I usually pay about 18baht for the 1/2" valve. About 59 cents. A wonder of modern industrialization.
Just discovered your channel, well probably I was manipulated by CZcams’s clever geometry (because algorithms are so cliche) to “discover” your channel. Just fantastic! Immediately subscribed and sharing. Oh, and I binged for at least on hour on your French chef friends channel thanks to you. I WILL NEVER go back to television. Ever. Because it will never be THIS good.
That was a truly amazing insight into the world of injection molding!!! I am prepared to bet that many of my colleagues in engineering, unless they have actually worked in the field, can learn a thing or two from this video!!!
I have absolutely no idea why I found this video so fascinating. I also don't understand the CZcams algorithm and how the hell they knew I'd watch this entire video😂😂
To get an part with a rubber grip for instance, we use what is called a 2 shot. The mold has 2 cavities. One cavity molds only the rigid material then the mold opens and one side rotates over and closes again. Then the soft shot shoots right on top of the rigid material. So the rotating side of the mold is the same on both top and bottom. The stationary side of the mold is set up to shoot rigid on one half and soft over top of the rigid on the other have. So there are 2 separate injection units on one press.
I'm redoing all the pipes in my house after the freeze here in Texas where we had no power for three days. Totally destroyed my pipes. Anyway, saw this video from 2017 and now I have some cool things to share with my wife. She's Canadian and views a trip to the hardware store as a hot date, so thanks for making my love life even better.
Made those Valves here in Germany.....you are a little bit wrong. You can see the different Letters on the side of the Valve ( E and D) those are different parts in different Molds/Tools. In the Factory there will be up to twenty machines and all they do all day long is producing one of those parts. One machine for Parts with the Letter A...another one with letter B and so on. The Letter tells you wich size of pipe will fit in the part. So Letter E means its for 1/2" on the intake side, and D is for the outgoing side. There is a small rim on the "E" that stopps the Valve Knob from making a wild 360 turn. So you have one machine per valve side and one machine thats produces the different knobs. Now comes the wonder of High frequency welding. Or like we call it in Germany. ...."Hochfrequenz Ultraschallschweißen" You place the first part in another machine, pipe side down in a special welding tool....a big massiv block of aluminum. the you place the central piece on top of this body. then comes the second Body part . You close the Welding machine and with the power of frequency you move the contacting surfaces of the parting line against each other. This generates enogth heat to melt the PVC on this line, and after a second the Welder presses the top part down so that the two halves become one. So you can produce milions of different bodyparts on stock, and you can combine them in post production (The welding step) like it pleases you. 1/2" Inch to 1"? No problem. Swap one welding tool for the one you like, and you are good to go. czcams.com/video/ddEnjwg1cF0/video.html Here...have a short video were they weld an medical filter body.....Have fun and take a like ;)
Ultrasound welding would have left some extra material coming out at the parting line, hence there would have been witness marks of removing those from the valve on the video. Those are definitely a product of overmolding (insert molding).
Start watching the video again from 7:20 on. He talks about the possibilities and there are definitely valves glued or welded from two parts, but this one is molded as a single piece.
I've spent some significant time working in a shop that makes injection molds, and repairs/services them, and the mold that made a valve like that would likely have tolerances big enough to chuck a cat through. However, in a shop like I worked in, where we mostly work on mold for the medical industry, our tolerances for critical components in the mold are + or - 2 tent-thousandths of an inch, sometimes, only + 2 tenths, a range of only .0002 inches! The precision that an injection mold can achieve is astounding, and the work that goes into making them is too. love the videos man, keep it up!
You mean that the egg came first and then they injected the chiken around it?
+
ha, but actually, the chicken embryo grows the shell around itself...
genius
What bugs me is the combination of words "injected" and "around". We need something like "exjected".
@@Armuotas The plastic is "injected" into the mold, sometimes flowing "around" other parts placed in the mold before hand, like in the case of this valve. "Exjected" sounds like all the plastic just spilled everywhere.
I just spent 15 minutes totally engrossed in the production of an extremely cheap ball valve. I’m glad you’ve chosen to use your powers for good and not evil Old Tony.
You can see the evil peaking through in the video where his son is wired into the DIY CNC router.
But isn't it made of that evil plastic?
Brilliant content old Tony, as a former plumber I found this amusing. Top work as usual.
+colinfurze was literally just watching your tie fighter build! I mean... it's no PVC valve... but not too shabby. ;)
Love your videos , Colin. One crazy plumber to another
My two favourite uncle's in one comment.
I hope you guys help out Alex the French guy with some of your metal work magic
Didn't expected to see a content creator consuming the content of another content creator, almost as if the youtubers ware like.. like me.. watching together shows we make... Like we are brothers...
Srry, I get star struck :3
This is the best plastic valve video that will ever be made.
Hi, Tony, I have worked in injection molding for the last 22 years. You are really close on most everything. The mandrel is called a core and that would be on the cavity half. You would load seal-ball-seal and the core pin on the core half would come up and preload the insert stack of the ball and seals as the mold closes. Around the periphery of the core side core pin will be another witness line that's the ejector sleeve. This is an ejector pin but tubular. This process is overmolding they call it insert overmolding. We do this with an aluminum hub in a steering wheel. The wrinkling opposite the gate is known as jetting. They just blasted the shot in too fast on the first stage of the shot before a flow front had time to form. Keep up the fantastic work you are one of my favorate CZcamsrs!
I learned a wee bit about injection molding when I worked for a plastics fabricating company. One cool thing I learned is that there is no "heater" involved in melting the plastic. The drive screw forces the plastic into an ever smaller space formed by the screw threads and diameter until it reaches the aperture and then it's in a liquid (or semi-liquid state).
There most definately is heaters, usually three band heaters, referred to as "zones" to keep the temperature stable and the plastic molten. Sure the shearing induces heat to the plastic, but you can't rely on that alone.
Well, maybe in different applications or materials? These were never discussed in the courses I took nor with the owner of the injection company I worked with. Now maybe technology has changed, we're talking 25 years ago......
Depends mainly on the type of part and production cycle (as parts per unit of time) of the mold. You have heaters on the injection machine and in some molds (depending on the part geometry, the time of each cycle, etc) you have hot runners (nozzles with heaters)
.
It's my understanding that the heater bands are there to maintain the temperature of the material in the barrel when the screw is not in play in fact a lot of our machines drop power to heater bands until the machine times out in order to save power that's normally on our ppf dedicated machines because the melting temp is lower then abs or pcabs also some molds have hot runners to maintain even heat threw out the mold and aid in the smooth flow of material
"Well I'm no plastic surgeon..." - Best line evar.
I missed that! Doh!
you could say it was ....... genious.
9:53 after hearing that line I had to take a look at the comments. Indeed the best line ever xD
“The patient died, but the operation was a success”
Yes got a solid chuckle
Are we just going to ignore how it was spinning by itself at 0:30
Yeah pretty much
A rod through one of the holes in his bench down to his rotary weld table underneath? I have no clue I don't even feel qualified to watch his videos let alone comment
Stop motion
@@jakemrcool that was my first thought but it would be such an intricate touch for it to skip along with his speaking... maybe yiure right I shouldn't put any level of detail past him
Perhaps the bench was vibrating
The patient died, but the operation was a success! Subd
Yeah, that was my valve. You owe me a valve.
Ed
I suppose you are not open for suggestions...
czcams.com/video/IiGTkl4fSx4/video.html
@@smickandily you can just type 4:11
I'm am a tool and die maker by trade. It nice to see someone appreciate the trade . Great video 🖒
Jeff Petersen I would live to see you make some videos and teach a sparky like me. I have a hobby lathe and I'm loving it but precision past tenths is amazing
and i am a Tool and Die apprentice in Germany in my 3rd year, a world where 0.1mm is way too much
Jeff Petersen yeah you should do how to videos in your free time I’m sure many people especially me would appreciate it
Jeff Petersen . As a custom molder who regularly had to deal with someone else's mistakes I appreciate a good tool and die maker and getting them involved on the front end of a project. A great way to loose money is chasing the cheapest tool price.
how do you say in germany tenths of mm are for woodworkers, hundreds are for metal ;)
I imagine this was assembled in brazil and the letters E and D stands for esquerda and direita ( left and right). 😂
Was that the AvE logo that popped out of the example mold near the beginning?
Surestick88 2:57 well spotted
I saw that too. had to rewind to make sure that's what it was.
Ave did the same video and I just watched it again before this, but it’s not in my history. Thank you guys so much because I thought I had just lost my mind.
lol mee too
the mold actually isnt a perfect negative, it also takes into account shrinking due to the cooling of the plastic which can be quite a lot. Which is also why mold making is a real art
Especially before Moldflow and similar software. Even after the mold is designed and fabricated you can change the part size slightly by changing the process conditions (but that tends to compromise cycle time).
The thicker bottom of the valve is probably intentional as well. I hypothesize that it would increase flow along the bottom where the plastic is injected versus the rest of the part allowing control of how the weld line forms at the top
I really liked this vid Tony. A series on explaining clever everyday items would make me happy :-)
Me too
Steve James I'll keep my eyes peeled!
In the mean time, you might want to check Engineer Guy.
Or how its made
You could call it "How it's made"
I'm not sure why I watched this through a year ago. And even less sure why I just watched it all again today!
I just watched this for a second time after and extended time, even though I recalled it very well, but this time with a focus on the writing, presentation, and production.
same but 6 months later
Because its *GENIUS!*
Your vids are great. Learning cool stuff and you make me laugh!
Humans 2 million years in the future; evolved ejector pins in the roof of their mouth.
Eddie Van Horn. You have an interesting brain to have envisioned that
Milk. Its the perfect solvent for peanut butter.
I find hot blackcurrant juice the preferred solvent. But only because Trichloroethene is no longer readily available (and tastes disgusting).
Imagine what that would do to the porn industry.
Are adult teeth just ejector pins for baby teeth?
you actually showed the cutting in the video... the fame has changed you...
Michal Kubrický: DIY to be fair he did do that operation gag
all for the plastic surgeon joke
A bit of doubleboost
This is really genius Sir. And I like the way you presented it, it was very funny informative and you provided right information at right time. This is the best 15 min of Tech video I have ever seen. I have not just earned how it is made but the process of how you approached it was brilliant. You made it so easy to understand. Thank you
"i've bondoed, sanded and primered and repainted all of my water valves...." hahhaahhahahahahahhaha
The invisible rotating display table was amazing, could stare at it for minutes.
I found it terrifying...
Azureus Rising lol
This is like AvE but with an intelligible explanation. Thank you for the video!
Yes. This Old Tony's version of a BOLTR. He did pay homage when demonstrating the mold.
And safe to post where kiddos like scouts and students can see it w/o their parents being upset.
You just don’t speak what ever language it is ave speaks. I think it somewhere between southern mumble and deep north Canadian
I imagine this was assembled in brazil and the letters E and D stands for esquerda and direita ( left and right). 😂
And NO profanities.
The E and D are called cavity ID . That way if there is a defect you can tell which cavity did it. Most tools make more then one part at a time. We have molds that make up to 36 parts at once. Oh yea I've been a tool maker for 30 years. You did an excellent video explaining basic molding and yes you are right about the over molding.
I love showing these videos to my two kids! Thank you! Much better than a “how it’s made” video. A real person, with a real brain, in their garage, doing stuff. ❤️
he cut my valve in half!!!
Hey Tony, how the hell did my ball valve end up in your shop?
Ed M
kiss it goodbye my friend. He hacked it all up. R.I.P Ed’s ball valve
"Genius is an infinite capacity for taking pains." Thomas Carlyle - and that is how I view your work Tony. And, of course the same goes for the patient developer of the ball valve you dissected.
This is quality video!
Nothing better than seeing the world through the eyes of the inner child. Best 15 minutes of my life that I've utilised so far today!
Coming from a design engineering background, it's incredibly refreshing to listen to someone else go through a similar analytical process as myself when presented with something that is a small work of genius ^_^ Very entertaining! I enjoyed the mental exercise of predicting your points before you said em! I'd love to see more like this in future =]
Wow! I've used hundreds of these pvc ball valves and it never occurred to me what a wonder of industrial technology they are. I think a 1/2" valve at the big box stores around here would be like $1.85. Unbelievable.
"Patient died, but the operation was a success."
Love your commentary and how you explain things in a funny way. Keep up the good work. Greetings from Germany.
your editing and camera work is consistently imaginative. wonderfully done sir.
This video is... genius.
I find the topic of injection molding really interesting, I never figured so much effort goes into minimizing cost.
Also, I like these 'kind of deep dive' videos.
go watch How it's Made, then.
Appl Tom . Just about everything Tony said was spot on but this is not even close to a deep dive. He did do a great overview though.
I understand injection molding, like just about everything these days, is a incredibly complicated subject, that's why I wrote "kind of deep dive".
What I wanted to say was I like this explainey type of video.
The different angle makes all the difference.
at least 10 degree difference.
That's what *she* said...
I knew some of this having worked on an injection molding line one summer but your explanation was much better. A few things I learned that summer: One some machines run much hotter than others, polystyrene takes only a little heat, PVC a bit more, and Polycarbonate is scary to mold. Two when a mold is blocked they like to crank up the heat even more, the foremen got localized 2nd and 3rd degree burns all the time when the molds would "clear" themselves. And three, all parts are made of either "virgin plastic" or regrind, Four flash and sprue always need to be trimmed from the parts, always. This is the job the noobs get and hated. You can also mold in thread inserts and all sorts of other interesting things.
tony is more funny than 98% of the channels that are out there to make you laugh. and that last 2% are just on par with him. i get more laughs watching this than actual blatant comedy skit/oriented shows/channels. Tony, your sense of humor hits home with me. i love it. that and im 26 and learning that i dont know shit about anything. i thought since i was a mechanic working on cars i knew a thing or two. but watching your channel has taught me i'm still a baby bird of the mechanical world. and by baby bird i mean an egg, but maybe the beak has made it through the shell, just kinda poking out. but every time it pokes out it says shit like "im a mechanic" so people think i know what i'm doing
I work in a factory doing injection molding for shoes, specifically rubber soles and plastic heels.
Despite most of the products we make need quite a high precision, we still use aluminium alloys molds that get banged really easy, but also the work time of those products are sometimes over the 3 minutes total between injection and cooling, also they all require quite some calculation to prevent mismatching once the rubber/plastic shrink after cooling, cause it can mean a size 10 sole could become a size 8!
At the injection mold factory I work at we also use aluminum for the motorcycle and bicycle grips. Everything else we use p10.
2 notes... Betting the "mandrel" is part of the whole mold. One seat and the ball are stuck to one side of the tool, and the other seat is on the other side of the tool, and when it comes together, the center seals on the ball itself. Part the second, the thicker on the bottom than the top is probably intentional so the plastic flows more reliably to the far side of the mold from the injection point.
czcams.com/video/LfiRGJYjgMs/video.html
That's what it look is going on here, except there is a mandrel attached to the ball for the handle to be attached later.
fdfoxter The only difference there was TOT's ball valve was made with a hot runner and your video showed a cold runner.
Most injection molding content on CZcams relates to simple obvious molds, like the axe-head packaging. Thank you for showing something more complex and amazing.
A truly amazing teacher is a rare gift, and I’m extremely grateful you’ve gifted us all with these lessons. I have an intense curiosity about how things are made, and your videos are the best satiety I’ve found. Thank you!
I’ve been looking for that valve!
12:40 - Moved up about 10, not 20. 20 would have made it 180, 220.
Thought that too, 20 thou is a fair amount of deflecton 10 sounds more reasonable
Yeah same here, .010 would've made both sides .200
Isn't the inner side of PVC fittings tapered tho? As in, if he put the caliper in further, it would read higher?
There was a video on the jerry can, where they enumerated all the ingenious design decisions made for such a simple looking tool. I loved it because I feel like brilliant engineering lives among us, every day, unnoticed.
I like videos like this that are, "let's take a few dollars of plastic and look at why this is absolutely brilliant."
So much effort and time spent on just the first minute. His dedication to mucking around in the shop is just marvellous. I salute you Tony.
Love watching AvE take stuff apart. Now This Old Tony is taking stuff apart too? CZcams just got better.
The thing is AvE usually puts them back together to show them work. This is missing some material now.
The only reason I’m reading comments is to see if anyone else would would notice the AvE reference
@@petederksen9300 the moulding example right?
@@petederksen9300 Yeah I was like wait a second that logo looks familiar!
@@petederksen9300 dido that.
My father was a mechanical engineer, and when I was very young I remember how amazed he was by the precision of the mouldings in the first Lego set he bought me - that would have been around 1963 or so, when the first of the modern style bricks were released. Up to then you either had Meccano nuts and bolts, or your construction toy either wouldn't go together properly or fell apart - well, there were some plastic construction toys that worked OK, but not by press-fits of perfect force. You are right, it is a miracle of modern engineering.
The truly amazing thing about LEGO is the absolute quality standard that has been maintained for over 50 years. Take one of the early LEGO pieces and it will snap onto a current production part just as crisply as two made 10 seconds ago. As to the shape of the bricks and their method of locking together LEGO the idea had been used before on products not up to the same quality level as LEGO. Interestingly there are free 3D printing files to make adaptor blocks to enable LEGO to be used with other building set styles. www.fastcompany.com/3054837/build-with-lego-knex-and-8-other-toys-at-once-with-this-free-universal-adapter-set So if you've got a 3D printer and kids (or grandkids) who do stuff with LEGO or any of the other brands it can open another world of possibilities.
I’ve been working in a plumbing warehouse the last 3 months and I see so much of this stuff everyday and I never really thought this deep into something so simple. Genius
the only genius wasnt only the people who designed the valve but also the person who made and presented this video. a really excellent vid. so many thanks
I laughed, I loved, I learned.... Well done Tony! (Seriously, this was one of my favorites. I hope you do more "how it was made" style vids in the future.)
The drill housing was likely made using multiple shot injection molding. The whole part being made in one tool. The red plastic would be shot first then then the tool would have inserts that would back off, just enough to make room for the black plastic, then the second shot would be injected. Check out multi shot injection molds, iv seen up to 4 shot molds, 4 separate plastics in one tool.
damn those things would cost like a 100,000$
from my understanding 7 figures is more accurate
For 100,000$ you might not get one simple mold made from tool steel.
Simple molds are about $1500 at Protolabs: www.protolabs.com/services/injection-molding/
@@krzysztofukawski2348 Probably $25,000 in China from P20.
i’ve used many of this valves over the years and not once stopped to appreciate how these are made. i love knowing how things work, how things come together and such.
i have a new found appreciation for pvc ball valves and whom ever designed these little marvels
A former Mechanical engineer and soon to be retired dentist I am always impressed with your video's. An incredible amount of work goes into them, the humour is priceless and the insight and intelligence you display never fails to amaze and entertain me. This injection moulded valve video was GREAT, I've seen the valve but never had the inquiring mind to figure out how they were manufactured. So thanks for the info AND the entertainment!
1:38 "How in the H E double canadian hockey stick..." 😂😂😂
We've got ourselves a BOLTR right here
I absolutely love your narrative style! Clear, concise and with a healthy portion of comedy to boot. Thanks for the fantastic entertainment
I love this stuff! The engineering involved in making a part work well, and cost so little, is amazing.
Nice to see you talking about my everyday job. Just a interesting fact ruberised handle is injected in one mould in one operation ;)
I been trying to get my head round how that works. No success so far.
Robert Leitch . One way to do it is with 2 injection units and a rotating platen on one half of the tool. Shoot the plastic part rotate half the mold close on another half of the tool having space for the rubber over molded grip and shoot it again with the other injection unit... or a third unit..
The way you defined the number 5 left a hand shaped mark on my knee.
Telling what it REALLY says would have been nice, though.
A buddy of mine has a big scrap yard and gets the old injection molding machines from a few big name manufacturers in our area.
They are absolutely huge despite the often small parts they make. I helped cut one up last summer that made parts the size of a popcan and the machine itself was 25 feet long and weighed about 20 - 25 tons!
Seal, bullet proof, got a good laugh out of me. Very good videos, keep up the great work. We need the younger generations to get educated in manufacturing and trades.
Please make more of this kind of video!
Its really interesting and i got some cool ideas for projects / solutions from it...
thx
Small point but I think at 12:45 you meant moved up 0.010", not 0.020" (which would take 0.01" off the top and add it to the bottom)
That is what I was thinking also, I was looking for a comment to see if anybody else caught it and agreed with me. Not saying this confirms we are right.
Nah I agree.
Clearly THIS Old Tony has gone senile to make such a human error. Unforgivable! I should just give up on this rubbish channel... ;-)
I had to scroll down a million posts to make sure I wasn't the only one wanting to comment on this ... phew!
I worked in the metal diecasting field for many years in my youth. That all came back to me watching this video. We also had some parts that had inserts that we put into the die so as to become one part when cast. And the part of the die that held the inserts were called cores. Sometimes the part required cores not inline perpendicular to the parting line and those required a moving core that would be put into place using its own hydraulic cylinder after the diet closed.
The two-story tall injection molding machines I used to work on and build molds for injected rubber and plastics at up to 5000 psi. The "shot" cylinder hydraulics worked at up to 3000 psi. I learned very quickly that even 1/2" grade 8 bolts and hardened steel dowel pins used in assembly of the mold cores and mandrels didn't stand a chance holding pieces in place against the forces of the incoming material "shot". Typically gate placements and runner lengths and size had to balance opposing material pressures and cancel out these forces, or parts, no matter how stout, would shift and part wall thickness would be inconsistent. I made my first complex mold (for a large rubber bellows similar in shape to a car's CV joint boot) bread and butter style, and the core was a series of sharp edged "flying saucer" shaped discs held together by a long 1" dia. bolt thru the center of about 12 stacked discs, varying diameters, 0.500" thick each (like a stack of hotcakes). The outer mold halves were made the same way, but the stacks were held together by a series of shorter bolts on different overlapping centers, and final facing of the mating surfaces was done last, so the outer mold halves essentially became permanent assemblies. The first trial shot was a disaster. The injected rubber penetrated between the discs and forced the discs apart against the closed ends of the mold, stretching the 1" high tensile steel center bolt and locking the mold closed with the core and part trapped inside. It took nearly 30 tons of hydraulic press, hammer and chisel, and pry bars to separate the mold halves, and the part came out in shredded tatters. I tried to increase the clamping force between the discs, but even with as many high strength 1/2" and 3/8" bolts added on peripheral bolt circles I could fit in there, the mold core expanded and locked up every time. I then re-thought the way the flow of the material shot caused it to wedged between the discs as the shot entered the mold. To keep it from forcing its way between the discs, I finally got it to work by adding 0.050" outside radius fillets in the "vee" where the discs came together. The incoming material flow was thus re-directed to flow across the parting line instead of wedging into it. As a bonus, it also eliminated nearly all of the witness mark and flash. I then applied for and received customer approval to add matching radii to the outer pleats of the bellows as well, after I demonstrated how much improved the product looked and functioned. Mold making luck and black magic, I guess...
A masterpiece of editing, especially the AvE part!
I must re-watch this video at a slightly different angle...
Fantastic! Fantastic explanation and timing. I followed along, wasn't swamped with extraneous details and learnt a lot. Thanks!
Please don't take this wrong. I do so enjoy an "intelligent" smart ass. Your informed dry wit makes me chuckle so often I must remember to make regular visits to the bathroom less I have an embarrassing accident at my age.
Fantastic video as usual
Genius!
No matter how simple the video This Old Tony always makes it interesting. Always looking forward to the next video from the best CZcams channel going GW
I don't know which is better, Tony's knowledge of how things work or his great and sharp humor. Glad I found your channel keep it up.
CSI This Old Tony... love it!
You should watch the engineer guy video on injection moulding too 👌👌
Sai Skanda seconded. Is that the one where he shows how well Lego is made?
I always get a kick out of your videos, well written, illustrated and presented. I love the subtle references, well placed most times, to other awesome CZcamsrs, keep up the fantastical work.
Used to work in the mold making and die casting business up around Erie, PA years ago. Go laid off and never went back. Loved the work, miss it in some ways. Can live vicariously watching your vids. Thanks.
That 5 inside the recycle sign does not mean it can be recycled 5 times. The 5 stands for PP. It can be 1-7 for plastics unless specified.
He didn't say it was the number of times it could be recycled. He said it was the number of times you'll get to use it before you lose it or run over it with your car.
12:43 wouldn't it have gone up only 0.010"?
Bro Beans , TOT knows better, he's just testing for the machinist viewer ratio...
The injection-moulded parts on Dyson vacuum cleaners are fascinating to look at - the metallic-looking additives allow you to see the flow and weld lines quite well.
Some molds are very simple and some are very complex indeed. Bottles - inject resin, rotate, cogitate, blow air in and then Freon. Viola bottle. Then there are those with holes and 4 dimensions... I think some of the fancy ones are Engine blocks and maybe calculators... Thank for the dissection!
Noone:
Absolutely noone:
CZcams Recommendations: here watch this video on injection molding of a PVC valve from 2 years ago
Me, who knows nothing about manufacturing and has never watched a video about anything like this at all: *watches entire thing and enjoys it*
Why would the video being a couple years old matter?
"Noone" lol
I buy these for my garden irrigation projects where I live in Thailand, except here they are blue PVC. Maybe has something to do with Elvis. Maybe not. I usually pay about 18baht for the 1/2" valve. About 59 cents. A wonder of modern industrialization.
Just discovered your channel, well probably I was manipulated by CZcams’s clever geometry (because algorithms are so cliche) to “discover” your channel. Just fantastic! Immediately subscribed and sharing. Oh, and I binged for at least on hour on your French chef friends channel thanks to you. I WILL NEVER go back to television. Ever. Because it will never be THIS good.
This was a perfect dissection of a valve, what a beautiful work.
I was just going to bed... Well I guess I am not sleeping tonight.
How did you slowly spin the valve? :)
My guess is filming it on Baby Right Round rotary table, then sprinkling it with a bit of magical editing pixie dust.
My guess: That yellow slow rotating welding table thing he build some time ago, with a axis going up through one of the holes in the table.
stop motion.
ajtrvll my guess: GENIUS
Vibration?
That was a truly amazing insight into the world of injection molding!!! I am prepared to bet that many of my colleagues in engineering, unless they have actually worked in the field, can learn a thing or two from this video!!!
I had wondered about these valves before, but it never entered my head that the ball might not be spherical. A good video.
I have absolutely no idea why I found this video so fascinating. I also don't understand the CZcams algorithm and how the hell they knew I'd watch this entire video😂😂
How was it spinning on the table 😭😭😭😭😭😭😭😭😭
It’s hanging from a thread just above the table. You can see the thread if you look close
To get an part with a rubber grip for instance, we use what is called a 2 shot. The mold has 2 cavities. One cavity molds only the rigid material then the mold opens and one side rotates over and closes again. Then the soft shot shoots right on top of the rigid material. So the rotating side of the mold is the same on both top and bottom. The stationary side of the mold is set up to shoot rigid on one half and soft over top of the rigid on the other have. So there are 2 separate injection units on one press.
I'm redoing all the pipes in my house after the freeze here in Texas where we had no power for three days. Totally destroyed my pipes. Anyway, saw this video from 2017 and now I have some cool things to share with my wife. She's Canadian and views a trip to the hardware store as a hot date, so thanks for making my love life even better.
Made those Valves here in Germany.....you are a little bit wrong.
You can see the different Letters on the side of the Valve ( E and D) those are different parts in different Molds/Tools. In the Factory there will be up to twenty machines and all they do all day long is producing one of those parts. One machine for Parts with the Letter A...another one with letter B and so on. The Letter tells you wich size of pipe will fit in the part. So Letter E means its for 1/2" on the intake side, and D is for the outgoing side. There is a small rim on the "E" that stopps the Valve Knob from making a wild 360 turn. So you have one machine per valve side and one machine thats produces the different knobs. Now comes the wonder of High frequency welding. Or like we call it in Germany. ...."Hochfrequenz Ultraschallschweißen" You place the first part in another machine, pipe side down in a special welding tool....a big massiv block of aluminum. the you place the central piece on top of this body. then comes the second Body part . You close the Welding machine and with the power of frequency you move the contacting surfaces of the parting line against each other. This generates enogth heat to melt the PVC on this line, and after a second the Welder presses the top part down so that the two halves become one.
So you can produce milions of different bodyparts on stock, and you can combine them in post production (The welding step) like it pleases you. 1/2" Inch to 1"? No problem. Swap one welding tool for the one you like, and you are good to go.
czcams.com/video/ddEnjwg1cF0/video.html Here...have a short video were they weld an medical filter body.....Have fun and take a like ;)
Ordog213 . czcams.com/video/LfiRGJYjgMs/video.html
What's your explanation for the injection gate that straddles the two halves?
Ultrasound welding would have left some extra material coming out at the parting line, hence there would have been witness marks of removing those from the valve on the video. Those are definitely a product of overmolding (insert molding).
Start watching the video again from 7:20 on. He talks about the possibilities and there are definitely valves glued or welded from two parts, but this one is molded as a single piece.
I am german and you are wrong are phrases often heard together.
I knew AVE had to have been mass producible.
That was really interesting - I was completely drawn in. Awesome knowledge and detail.. hat's off to you sir !
I never thought I'd see a seal in a bullet proof vest but thank you for proving me wrong.
ToT version of how it’s made??? I’d watch it!
Jesus Tony, you must be very "not boring" at parties
I think you spelled "fun" wrong.
I'm impressed! Both with the valve design and the presentation.
I've spent some significant time working in a shop that makes injection molds, and repairs/services them, and the mold that made a valve like that would likely have tolerances big enough to chuck a cat through. However, in a shop like I worked in, where we mostly work on mold for the medical industry, our tolerances for critical components in the mold are + or - 2 tent-thousandths of an inch, sometimes, only + 2 tenths, a range of only .0002 inches! The precision that an injection mold can achieve is astounding, and the work that goes into making them is too. love the videos man, keep it up!