Moving from 2D mould design to 3D modelling with Delcam’s PS-Moldmaker software has reduced significantly the design times needed by the CAD division of Korean toolmaker Kum-Nung Precision. The company was already using Delcam’s PowerMILL system for CNC programming within its CAM division and so now operates its complete design through manufacture process with Delcam software.

Kum-Nung Precision operates factories in Su-Won and Kwang-ju that generate a combined turnover of around $6 million. The company specialises in moulds for housings and other components for electrical appliances. More than 80% of its tooling is exported to Samsung factories in Japan.

PowerMILL was the first Delcam software to be used at Kum-Nung Precision, having been introduced early in 2004 following an evaluation during the second half of 2003. The successful introduction of the software, together with the support provided by Hankook Delcam with a very difficult project, encouraged the company to begin an evaluation of PS-Moldmaker.

A key part of the new evaluation was a benchmark undertaken on a mould for a cover for a compartment in a refrigerator, in which the Delcam software was compared with a leading competitor. While PS-Moldmaker was able to complete the project successfully, poor functionality in the competing program, coupled with the demonstrator’s lack of mould design experience, meant that it could not produce a finished design.

Important elements in the success of PS-Moldmaker were the ability to produce a watertight solid model from the imported component design data and the easy creation of the core and cavity using the Die Wizard. Similarly, the Cooling Wizard simplified construction of the cooling channels.

The company found the inclusion of the Futaba catalogue of mould bases within PS-Moldmaker’s standard range of catalogues particularly helpful. Users also appreciated the ability to create any additional components within Delcam’s PowerSHAPE CAD system and then to store them in the component library for later use.

When comparing the 3D methods with the earlier 2D process, it was found to be easier to modify the design. In addition, the Motion Simulation and Collision Checking within the 3D model gave extra confidence that the mould would perform as expected. All 2D drawings required could be produced successfully with Delcam’s 2D drafting package, PS-Draft, including the automatic generation of the Bill of Materials.

Overall the time taken with PS-Moldmaker, including that needed to produce the drawings, was three and a half days. This compared with seven days required with the old 2D system. With such impressive savings, it was perhaps not such a big surprise when Kum-Nung ordered six seats of the software.