filthy mechanical
500+ Head-Fier
Agreed, not on the consumer goods side of it but I've run into mold limitations industrially. There is this neat High Velocity Oxygen Fuel (HVOF) ceramic coating one of the 3 main machine OEMs makes that was amazing at my first shop taking a 500 heat mold to 2000 heats overnight, no mold powder change, no grade changes just the coating from nickel-chrome to this ceramic with all sorts of OEM special sauce. Go to the next job, since it is now a tube mold instead of 4 independent sheets of copper we can't get the machine head into the mold to apply the coating and have to stick to the nickel-chrome and the lower life. Had we been casting 1 inch larger in each direction billets the machine head would have fit. Never considered having 4 plates like below instead of a tube was such a limitation, but back with plate molds so we can do all sorts of fun stuff.And, if we go this way, it opens up new opportunities for light pipes (and other internal parts) with more flexibility in size and spacing...that don't have to be engineered to pop out of molds! I have to un-learn whole categories of stuff again, just like CNC vs stamping. You have no idea what kind of amazeballs it is when you don't have to consider mold limitations.
Caster mold for reference, the copper mold has a coating on it with varying thickness based on machine, grades cast, operating practice, CAPEX vs OPEX price breaks, etc: