Counter-molds for plaster: from breakage at every demolding to zero adhesion
The customer's challenge
A plaster parts manufacturer produced its parts using counter-molds that presented a recurring problem: they stuck to the plaster during demolding, causing part breakage and the resulting scrap and production losses.
The starting point was twofold. In addition to the breakage, the customer did not know what material had been used in the existing counter-molds, so there was no clear basis on which to seek an alternative.
Critical factor: without knowing the source material, any “on drawing” proposal was a gamble. It was necessary to test on the real line, not in the laboratory.
CTE's solution
CTE approached the problem in two phases. First it manufactured a short series of counter-molds in different plastic materials for the customer to test directly on its production line and identify, with real data, the material with the best demolding behavior.
Once the optimal material was defined, the tests revealed a second problem that no one had detected: the mold the customer had been working with, manufactured by a previous supplier, had a poor surface finish that contributed to adhesion. CTE manufactured a new mold with a polished finish, eliminating the problem at the root.
The result: clean demolding on 100% of the parts, breakage eliminated and a line that returns to producing without scrap.
Advantages delivered
01
Ideal material identified: the one that guarantees clean plaster demolding, chosen with data.
02
Complete diagnosis: the problem was not only the material; also the finish of the previous mold.
03
New mold with polished finish: perfect demolding and no part breakage.
04
Less scrap, more productivity: the line resumes production without stops or discarded parts.
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