Peter Cooke and son Richard started the business in 1977 and initially designed and manufactured specialised tooling for a variety of businesses.
Injection moulding production commenced shortly thereafter and backed by the tool design experience gained over the years has developed into the core business of the enterprise.
The business is run by a dedicated management team and competent staff who have developed skills and experience as the business has grown. Regular in-house and external staff training ensures the maintenance and improvement of operating standards. The company is committed to staff development and participation in training is encouraged.
The company operates from its own 1200 m2 factory centrally situated in Pinetown, and in close proximity to major supply routes.
A well established and modern computer network ensures the integrity and safety of electronic data, good communications systems, and accounting and administrative support for the company activities.
A 3D model and 2D drawings of the part need to be created to define clearly what the client requires and can expect delivered at the end of the process. These can be done in house or can also be supplied by the client.
From the 3D model the mould layout and engineering design is then done. All the critical decisions in terms of how the part will be created are addressed at this stage, with the overall objectives of maximising part quality and mould efficiency, and at the same time, simplifying the mould making process and choosing the correct tool steels for heat treatment to guarantee the expected mould life. It includes orientation of the part in the mould, mould shrinkage, feed of the plastic into the cavity (including mould flow analysis if required), cooling and de-moulding strategies. The component design may be altered to assist in resolving issues raised by the tool design. Once the overall layout of the mould is agreed, then steel can be ordered while the final design is completed.
The completed design is handed over to the tool room for construction. The 3D data of the mould parts are used for CNC programming, and the 2D data is used for manual processes. Depending on the volume demand expected from the mould, critical parts of the mould will be heat treated, either during the construction process or after try out, as required, to maximise the life of the mould. The final stages of the construction process are assembly and fitting of the machined parts together, as well as polishing of the cavities if required.
The completed mould is then subjected to a series of mould trials. Each trial may result in mould “tuning” corrective action being made, to resolve issues and improve the part. Once the mould is running satisfactorily, components will be measured against the 2D data to ensure that the part is within tolerance to prove if all of the client’s expectations have been met. Further alteration and re-trial will be made if required. Only once the component is accepted by the client is the tool making process complete and the mould can be transferred to production.