How to Remove Undercuts and Release Parts with Ease | Nx advance | Tool development

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An undercut refers to a feature on a part where a portion extends inward, creating a recessed area. While undercuts can be intentional design elements, they pose challenges during molding processes. When a part with undercuts is molded, the mold cavity cannot be directly pulled away from the part due to these features. This can lead to difficulties in part removal from the mold, requiring special techniques such as mold inserts, sliders, or mold splits to release the part without damaging it or the mold. These challenges can prolong production times and increase manufacturing costs if not addressed effectively.
To remove or avoid undercuts in molds, several provisions and techniques can be employed:
1. **Draft Angle**: Designing parts with draft angles allows for easier release from the mold. Draft angles are tapered features on the sidewalls of the part that facilitate its removal by providing clearance between the part and the mold.
2. **Core Pins and Lifters**: Core pins are protrusions inserted into the mold to create internal features of the part. Lifters are mechanical components that move within the mold to push or pull features of the part, allowing for the release of undercuts.
3. **Slides and Inserts**: Slides are movable sections of the mold that create additional mold features, enabling the release of undercuts. Inserts are separate pieces inserted into the mold to create specific features and help avoid undercuts.
4. **Split Molds**: Using split molds involves creating multiple mold sections that can be separated to release the part. This allows for the molding of complex parts with undercuts by providing access for part removal.
5. **Core Pulls**: Core pulls are mechanisms that operate within the mold to pull on cores or inserts, facilitating the release of undercuts. These can be hydraulic, pneumatic, or mechanical systems.
6. **Design Modification**: Sometimes, design modifications can be made to eliminate or reduce undercuts, making the part easier to mold. This might involve altering the geometry of the part or rethinking the design to minimize complex features.
By incorporating these provisions and techniques into the mold design, manufacturers can effectively address undercuts and ensure smoother part release during the molding process.
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