Design and Fabrication of Two Plate Molds for ID Card Holder Products using Injection Molding

Abstract

This study discusses the design  of a two-plate type mold  for ID Card Holder  products made of polypropylene (PP) using the injection molding process. The focus of the research includes the design of cavity and core inserts, the selection  of standard base molds, and the evaluation of mold assembly results. The research method is carried out systematically through the stages of 3D model design, CAM program creation, machining process, mold assembly, and printing trials. S50C carbon steel material is used as the main material of molds because it has mechanical strength and thermal properties suitable for tooling applications. The design results show that the two-plate mold with  the  2030 MFI standard mold base is able to meet the dimensional and structural stability needs. The calculation of the projection area of 12,902 mm² resulted in  a clamping force requirement of 64.51 tons, so that  the mold was declared safe to use in an injection molding  machine with a capacity of 80 tons. The resulting ID Card Holder product  demonstrates a geometric and functional fit with the initial design without significant visual defects.