Design and Modification of Cavity Plate for Injection Mold of Nail Polish Bottle Caps

In manufacturing industries, it is observed that a die in perfect condition was typecast as dead mold because the product was outmoded and that would be abolished due to space constraints, resulting in discarding such dies. This research paper discusses a system which is an alternative to save the dead mold from being discarded completely. The proposed system consists of designing a new cavity plate which would fit in the existing dies and results in making a single cap. This single cap can be used for two types of bottlenecks by modifying die design. This results in saving the manufacturing and material cost of making a new die and hence avoiding an existing die to go waste and preserving for any future requirements. So the whole idea of this work is to design and modify the cavity plate and with necessary changes which make it sustainable and yield more production. By replacing the bush from the existing cavity plate with CNC laser, removed the risk of flash on cap. With a sustainable approach in a design process besides the modification of the cavity plate and reusing an old die have resulted to recycle the by-products as well as production into the inners used for the same caps. In comparison with the existing die the production rate was increased by 29.6%.