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The difference is that urethane molding produces parts from silicone (soft tooling), whereas injection molding produce parts from steel or aluminum (hard tooling). Below is a quick overview showing you the difference between the tooling methods. Understanding the difference will help you keep your project on time, within budget, and give you properly functioning parts.

Working distanceoflens

-Steel/aluminum tools typically range in price from thousands to tens of thousands of dollars. And pending on the material and part geometry, the tool life can range from thousands to millions of parts.

Lenscalculator

To decrease the minimum working distance, you can use extension tubes, also known as calculating close-up rings. These tubes are placed between the camera and the lens, reducing the working distance. Depending on your needs, extension tubes of different sizes can be used. However, keep in mind that using extension tubes has some negative effects, such as increased lens distortion and reduced resolution.

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First, select the camera model and type. Then enter the lens focal length and the width you want to observe in millimeters. The working distance required for your setup will be displayed automatically.

You can use the tool in various ways, selecting two out of three parameters, “Lens Focal Length,” “Working Distance,” and “Image Width,” to automatically calculate the third parameter.

Effects 3 and 4 are the negative aspects of using extension tubes; therefore, their use is not recommended in some cases.

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Working distancevs focal length

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During the design of a machine vision system, besides the minimum working distance, it’s essential to consider the working distance constraint, which is the maximum distance at which equipment can be installed. This constraint is crucial for lens selection, considering mechanical limitations for equipment installation.

For example, in the image below, after selecting the camera model and type, a focal length of 12mm, and an image width (larger side in the image) of 150mm, the calculated working distance is 381mm.

Focal length

Industrial lenses have a parameter known as the minimum working distance, which represents the minimum distance you can approach an object. When choosing an industrial lens, ensure that the required working distance is greater than its minimum working distance.

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Hyperfocaldistancecalculator

The working distance, also known as the distance from the lens to the object, is a crucial factor in industrial lenses. It is measured from the front of the lens. The working distance is illustrated in the figure below, considering a rectangular object with length (V) and width (H).

-Silicone molds are typically injected with material that is manually gravity fed through a tube. Pending on the type of material, it can take anywhere between 1-24 hours to cure. Once the parts within the mold cure, the molds are manually opened, and any necessary finishing is done by hand.

Different molding processes require different types of tooling. It is important to utilize the correct process so that you receive properly functioning parts. The two most commonly used molding processes are urethane molding, and injection molding. A major difference between the two processes is the type of tooling used to produce parts.

-Silicone molds and the urethane process are used when a lower volume of parts is needed (1-100). This is because the tooling and piece price is more economical for lower quantities. On average, silicone tools usually cost in the hundreds to thousands of dollars, pending on the part geometry.

Sometimes, due to space constraints, you might want to reduce the working distance, but this can lead to lens complexity, increased lens cost, and decreased system performance. As a general rule, it’s better for the working distance to be 2 to 4 times the field of view. For example, if you want to view a rectangle with a width of 20 centimeters and a length of 15 centimeters, it’s advisable for the working distance to be between 40 to 80 centimeters.

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-Steel/aluminum tools are injected with material from an injection mold machine. The machine injects mold into the mold with less man-power when compared to silicone molds. The curing of material will take between a few seconds to a few minutes, thus yielding more parts much quicker than silicone tools.

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Keep in mind that when using extension tubes, you need to calculate the required length. If you need assistance in this regard, you can consult our team.

The image below shows a lens with a focal length of 12mm, manufactured by Basler. The minimum working distance is denoted by the parameter “Min Working Distance,” and, in this case, it is 100 millimeters. Therefore, this lens can be used at a distance greater than 100 millimeters.

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Working distancein microscope

For analyzing and designing vision systems, it’s essential to calculate the working distance. In Basler cameras, you can use a tool available on the Basler website. To do this, click here to access the tool, then follow the steps below.

-Silicone molds can be used for prototype, bridge and production of low volumes from one part to hundreds of parts. Most silicone molds are good for about 25 shots per cavity.

When designing a machine vision system, it is essential to carefully choose its components, such as cameras, lenses, lights, and more. For each component, including the camera, factors like resolution, shutter type, frame rate, and others need to be analyzed. One critical consideration when selecting a lens is the working distance.

-Steel/aluminum tools are used for the injection molding process for prototype or bridge, but these tools are mostly used for high volume production (100’s-100,000’s).

For instance, in a production line where you need to inspect the print quality on products, mechanical constraints may limit you to a maximum distance of 300 millimeters from the object (lens-to-object distance). In this case, choose a lens with a minimum working distance less than 300 millimeters.