---
title: Plate mould
slug: plate-mould
description: This tutorial demonstrates the creation of an aluminum mold for injecting a plate measuring 0.12 inches (3mm) in thickness. The plate is suitable for serving dry items such as nuts and various objects. It should not be used for direct food consumption unless a suitable coating or lacquer is applied.

For a demonstration of the plate's creation, visit: https://www.youtube.com/watch?v=YzjTm3FRLVY&t=5s

Special thanks to Paul Denney.
tags: ["PP","product","injection","mould"]
category: Moulds
difficulty: Medium
time: 1-2 weeks
location: Amsterdam, Netherlands (Kingdom of the)
---
import { Image } from 'astro:assets'
# Plate mould
<Image src={import('./mould_top_bottom-18391cdffca.jpg')} alt="Plate mould" />
This tutorial demonstrates the creation of an aluminum mold for injecting a plate measuring 0.12 inches (3mm) in thickness. The plate is suitable for serving dry items such as nuts and various objects. It should not be used for direct food consumption unless a suitable coating or lacquer is applied.

For a demonstration of the plate's creation, visit: https://www.youtube.com/watch?v=YzjTm3FRLVY&t=5s

Special thanks to Paul Denney.

User Location: Amsterdam, Netherlands (Kingdom of the)
## Steps
### Step 1: Get ready 

### Tools Required

- CNC machine, cutting tools (e.g., cutting pliers), drill, welder
- Protective gear: mask with ABEC filter, gloves, glasses
- Scale, sandpaper, metal polishing paste
- Four bolts, 5/16-inch (8 mm) diameter, minimum length 3.5 inches (9 cm), with nuts
- Two metal dowel pins, 1/4 inch (6 mm) diameter
- Drill bits, 5/16-inch (8 mm) and 1/4-inch (6 mm)
- Wrenches
- Two aluminum blocks, 10.2 x 10.2 x 1.6 inches (26 x 26 x 4 cm)
- Metal sheet, minimum 5.9 x 5.9 x 0.2 inches (15 x 15 x 0.5 cm)
- Plumbing connector, 1 inch 

### Machines Required

- Injection machine 
- Shredder or pre-shredded plastic


<Image src={import('./Screenshot_2020-02-03_at_23.27.49.png')} alt="Screenshot 2020-02-03 at 23.27.49.png" />

### Step 2: The mould

To create a plate using the injection machine, a three-part mold is necessary: a bottom part and a top part, both made of aluminum, and a connector part made of steel. The top and bottom parts will be CNC-milled from aluminum blocks, while the connector part will be fabricated manually.


<Image src={import('./mould_top_bottom.jpg')} alt="mould top + bottom.jpg" />


<Image src={import('./connector_bolds.jpg')} alt="connector + bolds.jpg" />

### Step 3: CNC your top and bottom parts

### CNC Part Instructions

1. **Download and Prepare Material**
   - Obtain the STEP file and use it to CNC-mill two identical aluminum blocks, minimum size 10.2 in x 10.2 in x 1.6 in (26 cm x 26 cm x 4 cm). Note: Moulds should not exceed a maximum width of 11 in (28 cm).

2. **Reference Points Milling**
   - The STEP file includes six reference points for precise manual drilling. If a CNC milling machine is unavailable, consider outsourcing to a CNC service provider, keeping in mind potential higher costs and delays.

3. **Mould Polishing**
   - After cutting, polish the mould for a refined surface finish. You can choose to polish it yourself or request this service from the CNC provider.

### Acknowledgment

Special thanks to Friedrich.


<Image src={import('./Screenshot_2020-02-03_at_23.13.17.png')} alt="Screenshot 2020-02-03 at 23.13.17.png" />

### Step 4: Drill the holes in the aluminium mould

We need to create holes in the mould parts. There are two types of holes required, making a total of six holes, excluding the injection hole, which will be addressed later.

First, drill two halfway holes on the inner sides of the aluminum (aluminium) blocks to accommodate metal dowel pins. These pins ensure the mould aligns correctly during injection. Drill holes corresponding to the dowel pin size you are using. For instance, if using 0.25 inches (6 mm) pins, drill accordingly. The mould will open and close more easily with use.

Next, drill four holes at the corners of the aluminum (aluminium) blocks for bolts and nuts to secure the mould. Use the marked drill indicators or align the mould properly to ensure correctness.


<Image src={import('./Screenshot_2020-02-03_at_23.26.12.png')} alt="Screenshot 2020-02-03 at 23.26.12.png" />


<Image src={import('./DSCF8581-edited.jpg')} alt="DSCF8581-edited.jpg" />


<Image src={import('./Screenshot_2020-02-03_at_22.29.31.png')} alt="Screenshot 2020-02-03 at 22.29.31.png" />

### Step 5: Drill the injection hole

Drill a hole (0.51 inches) in the center of the bottom mold part with a 13mm bit. This facilitates the flow of plastic from the injection machine into the mold. A central drill indicator is available in the STEP file.


<Image src={import('./Screenshot_2020-02-03_at_23.25.12.png')} alt="Screenshot 2020-02-03 at 23.25.12.png" />


<Image src={import('./Screenshot_2020-02-03_at_23.24.39.png')} alt="Screenshot 2020-02-03 at 23.24.39.png" />

### Step 6: Make the connector plate

To create the connection plate, acquire a square steel sheet measuring 59 inches by 59 inches (150 cm x 150 cm) with a minimum thickness of 0.2 inches (0.5 cm) and a nozzle compatible with your injection machine (e.g., 1/2 inch BSP type). Verify the connection types for the injector. Mark the centers for the holes following the drawing and drill accordingly. Position the nozzle over the 0.5-inch (13 mm) hole and weld it securely to the plate, ensuring it is precisely centered to facilitate attaching the mold and optimizing plastic flow. Precise alignment with the mold and injection machine is crucial, so maintain accuracy throughout the process.


<Image src={import('./Screenshot_2020-02-03_at_23.22.54.png')} alt="Screenshot 2020-02-03 at 23.22.54.png" />


<Image src={import('./Screenshot_2020-02-03_at_23.23.48.png')} alt="Screenshot 2020-02-03 at 23.23.48.png" />


<Image src={import('./Screenshot_2020-02-03_at_23.23.39.png')} alt="Screenshot 2020-02-03 at 23.23.39.png" />

### Step 7: Sand the mould edges 

The mold will be more user-friendly if you sand the sharp edges, as CNC-cut aluminum can be very sharp. Consider adding an inclined edge to the bottom part to facilitate opening and closing. It's essential to sand and polish the inside for a clean product finish. A polished mold yields a high-quality product, whereas an unpolished one appears rough. Use a wooden block with sandpaper to maintain straight sanding. Begin with 120-grit paper and double the grit size with each step (120, 240, 440, etc., up to 2000). Clean the mold with a cloth to remove aluminum dust—do not blow it out as it is harmful to your lungs. Follow with metal-grained steel wool and fine steel wool. Finally, polish the mold with a clean cloth and polishing paste.


<Image src={import('./DSCF8565.JPG')} alt="DSCF8565.JPG" />


<Image src={import('./DSCF8587.JPG')} alt="DSCF8587.JPG" />


<Image src={import('./DSCF8657.JPG')} alt="DSCF8657.JPG" />

### Step 8: Assemble the mould 

### Assembly Instructions

After preparing the mold, assemble the components. Connect the top and bottom parts using dowel pins for alignment, and secure with bolts and nuts. Attach the connector plate to the top and bottom parts of the mold. Your setup is now complete.


<Image src={import('./DSCF8719.JPG')} alt="DSCF8719.JPG" />


<Image src={import('./DSCF8715.JPG')} alt="DSCF8715.JPG" />

### Step 9: Get yo plastic!

Use PP, HDPE, LDPE, or PS, with PP and LDPE being most successful. The standard injector's maximum capacity is 150g (5.29 oz).


<Image src={import('./DSCF8798.JPG')} alt="DSCF8798.JPG" />


<Image src={import('./Screenshot_2020-02-03_at_23.17.28.png')} alt="Screenshot 2020-02-03 at 23.17.28.png" />


<Image src={import('./Screenshot_2020-02-03_at_23.16.47.png')} alt="Screenshot 2020-02-03 at 23.16.47.png" />

### Step 10: oh man! Injection time!  

### Injection Process Guidelines

1. **Material Loading**: Fill the injector entirely with material, avoiding overfilling to prevent it from adhering to the hopper or injector exterior.

2. **Temperature Settings**: Adjust temperature according to the specific melting point of the material. Set the lower heating element slightly hotter than the upper to prevent premature solidification.

3. **Injector Operation**: Move the injector lever up and down to push the material into the barrel. Add more material as needed and keep the handle down to maintain pressure. 

4. **Heating and Preparation**: After approximately 15 minutes of heating, lift the handle and open the injector. Trim any initial plastic drippings which may contain unmelted material and attach your mold to the injector.

5. **Safety Precautions**: Use a protective mask, eye cover, and heat-resistant gloves during this process to ensure safety.

6. **Plastic Injection**: Use maximum force to pull down the injector handle and achieve a continuous injection, maintaining pressure for 30 seconds. Avoid segmented pressing. If additional force is required, seek assistance.


<Image src={import('./DSCF8855.JPG')} alt="DSCF8855.JPG" />


<Image src={import('./DSCF8861.JPG')} alt="DSCF8861.JPG" />


<Image src={import('./DSCF8878.JPG')} alt="DSCF8878.JPG" />

### Step 11: Discover your creation

Keep the handlebar lowered. Quickly remove the mold from the injection barrel and re-seal the injector's connection point to prevent leakage. Use water to accelerate cooling. Once the mold has cooled, unscrew the bolts to open it. Use a hammer and pin to remove the plate via the nozzle connector at the top.


<Image src={import('./DSCF8889.JPG')} alt="DSCF8889.JPG" />


<Image src={import('./DSCF8904.JPG')} alt="DSCF8904.JPG" />


<Image src={import('./DSCF8907.JPG')} alt="DSCF8907.JPG" />

### Step 12: Finish the plate 

Trim the excess material at the injection point using sharp pliers. Sand any uneven areas for a smooth finish, using a machine or by hand if preferred.

*Disclaimer: 
As the source of the plastics cannot be fully verified, avoid consuming food from this plate unless a lacquer is applied to the surface.


<Image src={import('./Screenshot_2020-02-03_at_23.16.40.png')} alt="Screenshot 2020-02-03 at 23.16.40.png" />


<Image src={import('./Screenshot_2020-02-03_at_23.16.47.png')} alt="Screenshot 2020-02-03 at 23.16.47.png" />


<Image src={import('./DSCF8911.JPG')} alt="DSCF8911.JPG" />

### Step 13: Label your plastic! Stamp the plate!

At this stage, it is advisable to add a plastic type symbol to your product to indicate its composition. This assists future identification and potential recycling. Various techniques are available for stamping your material. Here, specialized stamps were utilized.


<Image src={import('./labelcoin.JPG')} alt="labelcoin.JPG" />


<Image src={import('./_DSC3526.JPG')} alt="_DSC3526.JPG" />


<Image src={import('./stamp.jpg')} alt="stamp.jpg" />

### Step 14: Finish like a heroe

### Completion Instructions

Enjoy a beverage of choice and appreciate your craftsmanship. For inquiries, feel free to email me at hoogewerfthomas@gmail.com or share a photo of your creation.

Witness the project in action in Panama: [Watch here](https://www.youtube.com/watch?v=YzjTm3FRLVY&t=5s).

Special thanks to Paul Denney.

#### Disclaimer
Since the plastic sources cannot be fully verified, avoid using the plate for food unless you apply a protective lacquer.


<Image src={import('./plates_660x440.jpg')} alt="plates 660x440.jpg" />


<Image src={import('./Screenshot_2020-02-03_at_23.15.46.png')} alt="Screenshot 2020-02-03 at 23.15.46.png" />


<Image src={import('./platepanama.jpg')} alt="platepanama.jpg" />