Lenard Tool & Machine, Inc.

United States

• Tightest Tolerances± 0.001”
• Project ScopeDevelopment of a mold with moving cores and ejected cavity plate for silicone mouthpiece for the safety industry.
• Overall Part DimensionsWall thickness: 0.050”
• Equipment Used to Manufacture PartCAD & CAM software, CNC milling, CNC turning, EDM, surface grinding, gun drilling, bead blasting.
• Mold Tooling Design Capabilities Applied/ProcessesPrimary: Mold Tooling Design Mold Tooling Production

A medicalsafety industry customer approached Lenard Tool & Machine, Inc. (LTM) to create a production mold for the manufacture of the silicone mouthpiece highlighted here. LTM utilized its fully developed suite of design and fabrication talent to construct a molding solution capable of accurately casting the mouthpiece. LTM worked closely with the customer while producing initial mold prototypes in a CADCAM environment. A horizontally-oriented injection press mold was formed, featuring heated cavity plates and an ejection system capable of moving the plates and mold cores. 420 pre hard stainless steel was specified for the material, giving exceptional surface hardness and wearability properties to the mold. Input and approval from the molder was implemented during the design phase. LTM fabricated the production mold design through a series of material removal procedures. CNC-type milling and turning were the primary processes, followed by refinement through surface grinding and bead blasting. LTM's excellent skill in mold tooling allowed for required casting wall thickness of 0.050" and tight tolerances of ±0.001." Subsequent validation of dimensional accuracy as well as functiona

• SoftwareAutoCAD (dwg, dxf) Delcam Powershape (dgk)
• General CapabilitiesDimensional Inspection Recreation of Obsolete Parts
• Engineering DisciplineMechanical
• TestingFunctionality Testing
• EquipmentGages Micrometers Calipers

• Reverse Engineering & Mold Fabrication Capabilities Applied/ProcessesPrimary: Reverse Engineering Mold Tooling Design Mold Tooling Production Product Design and Engineering – Modeling
• Tightest Tolerances± 0.001”
• Overall Part DimensionsCuff Wall Thickness: 0.030”
• Project ScopeLenard Tool worked with a doctor & molder to create product models, 2D drawings, tool designs, and tools to mold silicone parts that would then be glued together to create a re-useable silicone airway assembly.
• Equipment Used to Manufacture PartCAD & CAM software, CNC milling, CNC turning, surface grinding, bead blasting.

Lenard Tool & Machine, Inc. (LTM) was approached by a physician and molder to develop the reusable silicone airway assembly highlighted here. The airway assembly design was derived through reverse engineering; this also allowed the assembly to be reduced to five simple modeled parts. Once the product development was completed, LTM began design of the five molds, which included modeling, selection of fabrication processes, and the production of prototypes for product qualification. The resulting liquid injection book molds were created utilizing CNC milling and turning, surface grinding, and bead blasting, on pre-hardened 420-stainless steel. It featured cuff wall thickness was 0.030, " and tolerances were kept at ±0.001." The final produced design was validated for proper operation and geometry. With a speedy turnaround of only four months, LTM delivered a cost effective solution for this mass produced molded product, and was retained by the customer for future design modeling and mold production. Lenard Tool and Machine demonstrated an unsurpassed ability to serve the customer's unique needs and keep them integrated into every step.

• Equipment Used to Manufacture PartCAD & CAM software, CNC milling, CNC turning, surface grinding, bead blasting.
• Overall Part DimensionsCuff Wall Thickness: 0.010”
• Tooling Design & Fabrication Capabilities Applied/ProcessesPrimary: Mold Tooling Design Mold Tooling Production
• Project ScopeDevelopment of a mold with exploding cavities inserts to mold a silicone cervical cap
• Tightest Tolerances± 0.0005”

Lenard Tool & Machine, Inc. (LTM) was selected by a manufacturer of medical devices to create a high-performance mold for the production of the silicone cervical cap highlighted here. Initial product development revealed that the mold design would have to address the unique challenges posed by the geometry of the cervical cap. Mold design took place on CADCAM software, and integrated all of the complex customer specifications. The mold design LTM produced coped with these constraints by utilizing exploding cavity inserts and a flip-out core bar with cores attached, all constructed out of sufficiently hard-420 stainless steel featuring a RC of 50. Input and approval from the molder concluded the design phase. CNC milling, turning, surface grinding, and bead blasting were utilized to produce the mold. Tightest tolerances were held at ±0.0005" with cuff wall thickness of 0.010". Dimensional inspection and validation of functionality ensured proper operation and geometry in the produced design.

• Tightest Tolerances± 0.001”
• Overall Part DimensionsWall Thickness: 0.2”
• Equipment Used to Manufacture PartCAD & CAM software, CNC milling, CNC turning, EDM, surface grinding, gun drilling, bead blasting.
• Mold Making Capabilities Applied/ProcessesPrimary: Mold Tooling Design Mold Tooling Manufacturing
• Project ScopeDevelopment of a cold runner, cold drop injection mold with rotating core bars to mold an AEM Intake Elbow for the automotive industry.

Lenard Tool & Machine, Inc. (LTM) was approached by a US-based auto industry customer to produce a mold for the Ethylene Acrylate (AEM) Intake Elbow highlighted here. LTM's development of the mold design would have to accurately reproduce the nuanced geometry of the elbow while still providing a high-performance and cost-effective solution. Design of the mold commenced on CADCAM software, integrating the requirements of the customer and the complex geometry of the elbow. LTM specified a mold layout incorporating cooled runners and drops, along with heated cavity plates and cores. This setup allowed for an efficient balance between cost and injection cycle time. LTM's design also incorporated its own press mounted rail system for core bar installation, which doubles production rates by employing paired sets of cores. Pre-hardened 420 stainless steel was selected as the material for the cavity plates, and 1144 steel for the cores. Fabrication utilized CNC milling and turning as the primary manufacture processes, along with electron discharge machining (EDM), surface grinding, bead blasting, and gun drilling. Wall thickness was set at 0.2" and tolerances were kept at ±0.001." A complete validation of mold geometry and functionality was done to guarantee performance in the completed mold. LTM's expertise in mold design and manufacture provides a critical advantage in the context of injection molded production. With an impressive turnaround time of only 12 weeks, a comprehensive, high performance solution was delivered to the customer featured here. Although only one example, LTM has rendered many similar experiences to its customers, combining efficient, experienced-driven design with their needs to create high-performance, cost effective molding solutions. Contact LTM today to learn how you can take advantage of these features and more.

• Equipment Used to Manufacture PartCAD & CAM software, CNC milling, CNC turning, surface grinding, bead blasting.
• Mold Development Capabilities Applied/ProcessesPrimary: Mold Tooling Design Mold Tooling Manufacturing
• Project ScopeDevelopment of an injection mold with shuttling core bars with attached slide away cavity bars to mold an EPDM diaphragm for the automotive industry.
• Overall Part DimensionsWall Thickness: 0.032”
• Tightest Tolerances± 0.001”

Lenard Tool & Machine, Inc. (LTM) was contracted by a US Automotive firm for the creation of an injection mold for the EPDM diaphragm featured here. Initial assessments revealed that LTM would have to design a high quality, cost-effective mold solution capable of casting the intricate layout of the diaphragm. Design of the mold was performed in CADCAM software, taking into account the customer's specific requirements as well as the complex geometry of the diaphragm. LTM created a design that incorporated its own T-slot core bar shuttling technology, in the form of cavity bars that slide out with the core bars. A de-molding fixture was custom designed to allow for easy de-molding from these specialized cores. Input from the molder was included throughout the design phase. The fabrication process was specified to contain CNC-based turning and milling for the primary material removal, along with bead blasting and surface grinding procedures. This allowed for excellent dimensional precision in the 0.032" part thickness, with tolerances of ±0.001". 420 pre hardened stainless steel was employed for the cavity plates and bars, as well as the core bars. A full evaluation of geometrical accuracy and mold operation was carried out after fabrication. Delivered in only 6 weeks, LTM brought to the customer a well-engineered, high-performance product that was designed with their needs in mind. An industry-leading ability to bring a comprehensive and cost-efficient molding solution in a timely manner was strongly demonstrated here.

• Tightest Tolerances± 0.001”
• Overall Part DimensionsOD: Ø 0.2” Length: 0.7”
• Equipment Used to Manufacture PartCAD & CAM software, CNC milling, CNC turning, surface grinding, bead blasting.
• Design & Fabrication Capabilities Applied/ProcessesPrimary: Reverse Engineering Mold Tooling Design Mold Tooling Production Product Design and Engineering – Modeling
• Project ScopeProduct and tooling development for new silicone wedges for the dental industry.

Lenard Tool and Machine, Inc. (LTM) was approached by a dentistry customer to develop a molding solution for the assorted silicone dental wedges highlighted here. The mold design was derived through reverse engineering of the customer-supplied wedges. LTM worked closely with the customer as well as the molder to ensure that the intricate geometries were fully integrated into the design. A CAD prototype of a four-cavity family mold was created, and submitted to the molder for input and approval. The mold was then fabricated and submitted to the customer for additional review. Further revisions added cavity inserts that widened the variety of varying wedge models that this molding solution would produce. Fabrication utilized a series of processes to create the mold. CNC milling was the primary construction method, along with surface grinding and bead blasting. 420 stainless pre hardened steel was selected as the mold material, offering important qualities of high hardness and excellent wearability. The synergy of these factors resulted in a mold with precise casting abilities and dimensional tolerances of only ±0.001." Fabrication concluded with a comprehensive validation of proper operation and dimensional accuracy. A well-engineered design, coupled with quality tooling and a quick delivery time of only 3 months gave the customer a convenient, long-lasting, and cost-efficient injection molding solution. LTM displayed a stellar capability in answering a customer's needs in the conception and delivery of this project.

• Tightest Tolerances± 0.005”
• Mold Design Capabilities Applied/ProcessesPrimary: Mold Tooling Design Mold Tooling Manufacturing Product Design and Engineering – Modeling
• Project ScopeProduct and tooling development for silicone decorative light pop-ons
• Overall Part DimensionsThickness: Varies
• Equipment Used to Manufacture PartCAD & CAM software, CNC milling, CNC turning, surface grinding, bead blasting.

When approached by a Home Décor Industry customer to develop the silicone light bulb decorations shown here, Lenard Tool & Machine, Inc. (LTM) delivered a comprehensive production solution. LTM called upon its experienced design and fabrication talent to completely address the customer's needs in a timely manner. Design of a solution was oriented towards creating a durable, reliable molding system for the silicone decorations. Customer-supplied design sketches were used as a foundation for CADCAM modeling of the decorations themselves, followed by the creation of molds to produce each unique decoration. Continuous communication was maintained with the customer to ensure adherence to the design intent. CNC milling and turning, along with secondary surface grinding and bead blasting were utilized on 420 stainless steel to create production molds. LTM's unparalleled tooling capabilities allowed the manufacture of a precise, high-performance mold with strict tolerances of only ±0.005." Dimensional and operational checks concluded the fabrication phase, ensuring that a dependable mold system was delivered.

Lenard Tool & Machine, Inc. (LTM) was approached by a physician and molder to develop the reusable silicone airway assembly highlighted here. The airway assembly design was derived through reverse engineering; this also allowed the assembly to be reduced to five simple modeled parts. Once the product development was completed, LTM began design of the five molds, which included modeling, selection of fabrication processes, and the production of prototypes for product qualification. The resulting liquid injection book molds were created utilizing CNC milling and turning, surface grinding, and bead blasting, on pre-hardened 420-stainless steel. It featured cuff wall thickness was 0.030, " and tolerances were kept at ±0.001." The final produced design was validated for proper operation and geometry. With a speedy turnaround of only four months, LTM delivered a cost effective solution for this mass produced molded product, and was retained by the customer for future design modeling and mold production. Lenard Tool and Machine demonstrated an unsurpassed ability to serve the customer's unique needs and keep them integrated into every step.

Lenard Tool and Machine, Inc. (LTM) was approached by a dentistry customer to develop a molding solution for the assorted silicone dental wedges highlighted here. The mold design was derived through reverse engineering of the customer-supplied wedges. LTM worked closely with the customer as well as the molder to ensure that the intricate geometries were fully integrated into the design. A CAD prototype of a four-cavity family mold was created, and submitted to the molder for input and approval. The mold was then fabricated and submitted to the customer for additional review. Further revisions added cavity inserts that widened the variety of varying wedge models that this molding solution would produce. Fabrication utilized a series of processes to create the mold. CNC milling was the primary construction method, along with surface grinding and bead blasting. 420 stainless pre hardened steel was selected as the mold material, offering important qualities of high hardness and excellent wearability. The synergy of these factors resulted in a mold with precise casting abilities and dimensional tolerances of only ±0.001." Fabrication concluded with a comprehensive validation of proper operation and dimensional accuracy. A well-engineered design, coupled with quality tooling and a quick delivery time of only 3 months gave the customer a convenient, long-lasting, and cost-efficient injection molding solution. LTM displayed a stellar capability in answering a customer's needs in the conception and delivery of this project.

When approached by a Home Décor Industry customer to develop the silicone light bulb decorations shown here, Lenard Tool & Machine, Inc. (LTM) delivered a comprehensive production solution. LTM called upon its experienced design and fabrication talent to completely address the customer's needs in a timely manner. Design of a solution was oriented towards creating a durable, reliable molding system for the silicone decorations. Customer-supplied design sketches were used as a foundation for CADCAM modeling of the decorations themselves, followed by the creation of molds to produce each unique decoration. Continuous communication was maintained with the customer to ensure adherence to the design intent. CNC milling and turning, along with secondary surface grinding and bead blasting were utilized on 420 stainless steel to create production molds. LTM's unparalleled tooling capabilities allowed the manufacture of a precise, high-performance mold with strict tolerances of only ±0.005." Dimensional and operational checks concluded the fabrication phase, ensuring that a dependable mold system was delivered.

At Lenard Tool & Machine, Inc. we provide advanced tool design and manufacturing for the elastomer molding industry. Our experienced team can provide 2D and 3D CAD modeling, prototypes, testing, and technical support. We can design and manufacture compression molds, hot or cold runner injection molds, hot or cold transfer molds, LIM book molds, to run in vertical and horizontal molding presses. Our team can also add additional tooling options such as extrusion pin and die sets, demolding devices, and clicker die sets, just to name a few. A large range of materials are available for our tools that include pre-hard stainless steel cavity plates, 4140 pre-hard cavity plates, 1144 plates and cores, and H13, S7, 420 SS and 440 SS heat treated cavity inserts and cores. We can send out cavity plates, inserts and cores to be plated as well. Some examples of the materials that are run in our tools include Silicone, EPDM, Neoprene, Viton and natural rubber. We offer many processes for tool manufacturing which include, blanchard and surface grinding, CNC milling, CNC turning, sinker and wire EMD, bead blasting and welding. Our product dimensions are all part and press specific and can range in length and width from 4" to 42" and 116" to 16" in height. At Lenard Tool and Machine we guarantee our product with quality checks during the design phase and tool fabrication to verify customer specifications, in addition to dimensional and functionality inspections. Our tolerances are part specific and can range between ±.0005" to ±.001". Our lead times are quoted on a job by job basis and emergency and rush services are available. For more information on our tool design and fabrication capability, see the table below, or contact us directly.

Lenard Tool & Machine, Inc. provides custom product design and engineering ideal for customers looking for full service tooling prototype to production capabilities. The Lenard Tool's engineering team offers consulting, testing, and material selection. Design assistance, including engineering and development, in addition to prototyping can be incorporated into the tooling project. The engineering team utilizes Autodesk's CAM software for modeling and drawing, and Delcam's CAD and CAM software for manufacturing. The advanced software capabilities of the Lenard Tool's engineering department benefit the customer with options to modify models and drawings to offer cost reductions in tooling, molding, and demolding. Lenard Tool's design and engineering, team can provide a wide range of tooling types to satisfy customer specifications. Additional documentation, integration, reverse engineering, and technical support can also be offered at the customer’s request. Each project is quoted on a job by job basis. Emergency and rush services are available. For more information on the Lenard Tool & Machine custom product design and engineering capability, see the table below, or contact us directly.