MULTI-CAVITY MOLDS NEED TO BE BALANCED TO GUARANTEE PARTS WITH THE SAME CHARACTERISTICS
Custom plastic molding company provides a balanced mold. Generally, it happens with the same injection time and the same pressure in the cavity. The filling of the cavities must come in a uniform way. Moreover, the stages packing and retention will have the same effect on all the pieces.
A cavity fills less than another in the filling stage. When performing the holding phase, it will generate a greater pressure in the cavity and as a consequence a part with “dimensions greater” than the rest.
CONTROLLING THE PRESSURE WITHIN THE CAVITY
As a good process technician in custom plastic molding company you must make sure that the mold you are injecting meets a good balance. Moreover, this is easy to do through fill studies and verify the variation or standard deviation does not exceed the limits allowed.
If you detect a variation outside the limit, now the task is to discover the cause that originates it, which can be one of the following lists:
- Material below processing temperature.
- Poor homogeneity in the temperature of the melt.
- Moreover, Geometric difference in flow and gate channels.
- Differences in the installation of degassing zones clogged or poorly designed vents.
- Similarly, Bad design of the piece.
- Bad distributor design.
- In addition, temperature differences in mold cooling.
- Temperature differences in the hot runner and injection points.
- Furthermore, injection speeds not adequate.
- Rheological flow of plastic in distribution channels.
WHAT IS COOLING?
The action of withdrawing energy from the plastic parts inside a mold provide by custom plastic molding company is known as the Cooling stage. This corresponds to the longest phase of the cycle time. Therefore, great attention is important in estimating the ideal cooling time in our processes, in order to obtain the most appropriate costs.
WHEN COOLING STARTS?
The cooling of the plastic begins as soon as the material has contact with the mold, either in the cold channel or in the walls of the cavity. The greatest heat removal occurs during the programmed cooling time, which begins in the vast majority of injectors at the end of the holding time.
However, in some equipment it is possible to program the start of cooling at the beginning of the holding stage.
WHAT IS THE STIMATED COOLING TIME?
The cooling time is easy to estimate based on the wall thickness of the part and the plastic in question? The cooling time is exponential to the thickness of the wall of the piece, the greater the thickness, the required cooling time increases. In our Injection Process Optimization course in custom plastic molding company we provide a useful Excel Calculator for cooling time.
WHAT WILL BE THE THICKNESS OF THE WALL?
- To guarantee an effective cooling time, it is important to design parts with wall thicknesses between 0.65 and 3.8 mm. Each plastic has an ideal thickness range. There are other factors that affect the cooling of the part for example:
- the thermal diffusivity of the plastic
- And the temperature of the mass.
However, the wall thickness is the value that has the greatest effect on the cooling time.
WHAT IS THERMAL DIFFUSIVITY?
According to custom plastic molding company all plastics have a different ability to diffuse the heat from their interior. It is famous as thermal diffusivity and comes by dividing the thermal conductivity of the material with the product of the value of its density and specific heat.
HOW COOLING TIME CAN BE INCREASED?
The higher the temperature of the dough, the amount of heat removes inside the mold increases. Therefore, the cooling time increases. It is important to work with the temperatures indicated by the supplier of the raw material.
The temperature of the metal in the mold is different from the temperature of the water flowing through its cooling ducts.
WHAT IS THE ROLE OF THERMAL DESIGN?
A suitable thermal design by custom plastic molding company has to guarantee a uniform cooling in the piece, and maintain a heat removal at a constant temperature. The pieces are required to cool with the same speed in all their sections, on the contrary, pieces with different dimensions and levels of contraction can be obtained.
WHAT WILL BE THE RESULT OF SMALLER HOSES?
Before making the hose connection, it is essential to identify the coolant inlets and outlets or passages in the mold. Do not connect molds if the cooling circuit is not clearly identified.
Check the diameters of the mold connections and avoid using connectors or hoses with smaller diameters than important. Furthermore, the reduction in diameter results in an increase in pressure drop and low refrigerant flow.
WHY WE HAVE TO AVOID SERIES CONNECTION?
Custom plastic molding company suggests avoiding making series connections by placing jumpers, as this does not create uniform cooling of parts. The parts that are at the beginning of the flow receive a lower temperature than those that are at the end. The series connections generate contraction differences in the pieces, therefore, dimensional variation.
WHAT IS THE IMPORTANCE OF TEMPERATURE?
It is important to examine the temperature of the water entering and leaving the mold. And it determines the temperature drop for each cooling duct. A drop of less than 3 ° C is important to ensure uniform heat removal. When the temperature differential is higher than important, the we should inspect the mold as the cooling ducts may be dirty.
HOW EFFECTIVE COOLING CAN BE ACHIEVED?
The effectiveness of cooling in a mold gets by maintaining turbulent flows in the cooling ducts. According to custom plastic molding company a turbulent cooling flow is more effective at removing heat than a laminar flow. To guarantee the turbulent flow in the cooling ducts of the mold a certain Reynolds number must be generated.
WHAT IS TRANSITION FLOW?
The interval between 2000 and 4000 is considered as transition flow and for values greater than 4000 it is considered as turbulent flow. The Reynolds number is a dimensionless number that relates the physical properties of the fluid, its velocity and the geometry of the pipe through which it flow.
In this article you can learn in detail how to calculate the Reynolds number.
WHAT IS REPRESENTED BY PRESSURE DROP?
The pressure drop represents the opposition of the flow of water entering the mold. Pressure drop is an indicator of flow restriction mainly by:
- dirty pipes
- blocked pipes
- incorrect connections
- use of smaller diameter pipe.
OPERATION OF A DEHUMIDIFIER FOR PLASTICS
In tri state plastic molding company the pellets are dosed through a loading system. The pellets deposit in an insulated hopper. It prevents the plastic from contacting the external environment. Hot, dry air enters the drying hopper from the diffuser cone. Air flows evenly through the material, heating it to the temperature described by the material manufacturer.
At the appropriate drying temperature, the molecular attraction between the polymer and the humidity weakens. The released water molecules diffuse and moves towards the surface of the pellet. Here the dry air absorbs them and carries them to the air outlet return at the top of the hopper.
Moisture-laden air passes through a filter to remove fines and other potential contaminants. If necessary, the return air passes through a heat exchanger to reduce its temperature to less than 150 ° F (65 ° C) before it enters the desiccant bed. Relatively cool and relatively humid return air flows through the desiccant, where it gives up its moisture.
A process air blower forces the dry air through a heater and back into the drying hopper. It is to start the cycle again in tri state plastic molding company. Ambient air enters the regeneration circuit through a filter. The air comes by the regeneration blower. The regeneration air heater raises its temperature to 425 ° F (218 ° C) before it enters the desiccant bed offline.
What will be the tri state plastic molding temperature?
At these temperatures, the moisture holding capacity of the molecular sieve desiccant is very low. The hot regeneration air increases the temperature of the desiccant. It begins to release adsorbed moisture and the moisture laden air vents to the atmosphere through the moisture outlet port.
The moisture expelled from the desiccant during regeneration consumes a considerable amount of the regeneration heat. So the outlet air temperature will be low typically 200 ° F (93 ° C). After the adsorbed moisture has been purged from the desiccant, the outlet air temperature will rise rapidly. It comes to a level approaching the regeneration inlet air temperature according to tri state plastic molding company.
What is the spindle turning speed or tangential speed (RPM)?
It is a programmable and decisive value to carry out the dosage correctly. For example, it guarantees the heating and homogenization of the melt, especially in semi-crystalline materials.
WHAT IS THE DOSAGE IN PLASTIC MOLDING?
In injection molding there is a term common as dosing. It corresponds to the action of loading into the injection chamber enough molten plastic to fill the cavities of the mold. The dosage carries out by the accumulation of material in the injection chamber. It is common by the action of the rotation of the screw. The pressure comes in the injection chamber forces the spindle back to a programmed value.
As explained by a tri state plastic molding company, the plastic heats up to a greater extent. It is due to the effects of friction provided by the spindle and the cylinder (approximately 80%). Therefore, at higher dosing speeds, the cutting forces in the plastic increase. It is gaining heat, which could to some extent, favor the process.
HOW TO PROGRAM THE TURNING SPEED?
Injection molding machines offer different programming options. The vast majority are programmed in RPM. In this option the number of turns that the spindle will make during one minute is programmed. Each machine has a maximum RPM capacity. It comes on the size of the spindle diameter.
Tri state plastic molding company says that for different screw diameters and at the same speed in RPM, the screw will travel at different tangential speeds. At a larger diameter and the same amount of RPM, the spindle travels a greater path. Because the perimeter of that circumference is greater, therefore, the tangential speed is also greater.
RULE FOR TURNING SPEED
There is a rule in molding that indicates that the spindle turning speed must be programmed according to the desired dosing time. It must be less than the closed mold time (at least one to two seconds). If the rule is met, the mold will open seconds after dispensing is complete, reducing spindle idle time.
There is a risk that the mold opens when the dosing stage is comes out in a tri state plastic molding company. It generates a pressure drop in the injection chamber. Although there is the possibility of avoiding the effects through valve molds and sealing nozzles the recommendation. It is to try to finish the dosage before the end of the cooling time.
RULE RESTRICTIONS FOR TRI STATE PLASTIC MOLDING
It is acceptable to apply this rule to most parts. However, it is not important to apply it in processes where cooling times are long and dosing times are short. In this case, the dosing rate can be so low that little shear stress would apply to the material affecting its homogeneity and heating in a tri state plastic molding company.
The recommendation for programming the speed of the spindle rotation comes by the manufacturer of the plastic. However, it is a misleading data since the manufacturers offer speed values in (rpm) revolutions per minute. But do not specify in which diameter of screw. And it is not the same speed to dose 200 rpm in a screw of diameter of 90 mm to one of 40 mm, the tangential speed will be different.
MY FINAL RECOMMENDATION
Tri state plastic molding company recommends for programming the spindle turning speed comes on first knowing the maximum tangential speed that the plastic can withstand. For example, Polypropylene (PP), which is a highly crystalline plastic. It supports dosing speeds of up to 1.3 m / s. This is a high speed compared to other materials such as Acetal (POM).
There are a lot of options you can choose for molding. I would suggest you to hire a professional plastic molding company for future project. Moreover, you can negotiate the price of injection molding if you are going for bigger project.
IDEAL FEED THROAT TEMPERATURE
Feed throat temperature is a variable that is often overlooked in the molding process and provides many benefits in plastic injection molding companies in USA. When an empty hopper is not the reason for a flow restriction in the throat, there is a possibility that the restriction comes by a plastic clogging at its inlet.
In general, this occurs due to overheating derived from a prolonged stoppage of the injector. The programming comes on a very high temperature in the feeding zone. It can be also due to a bad programming in the drying conditions. Even for maintaining a long dosing career. In general, the most current injection machines have a cooling system in the throat, in order to keep it fresh at all times.
What is throat temperature?
Throat temperature is a variable that we often overlook in the molding process except plastic injection molding companies in USA. If we control it, the conditions improve when transforming hygroscopic plastics and / or of high thermal behavior. Programming a correct temperature in the throat section promotes the free flow of the plastic that passes through it.
What is the recovery time?
In a robust molding process, the recovery time of the material has to be repetitive to achieve this condition. The supply of the material has to be constant; therefore, the tempering that we maintain at the entrance of the cylinder will be decisive so as not to restrict the flow. Throat tempering is programmable in the vast majority of machines.
For hygroscopic polymers plastic injection molding companies in USA recommend that the temperature is not below 55º C. On the contrary, the humidity present in the air and the volatiles expell from the cylinder can condense on the cold area. The accumulation of water on the surface of the throat can cause aesthetic defects and in other polymers it can generate hydrolytic degradation.
HOW TO DETERMINE THE VISCOSITY GRADE OF A PLASTIC
Surely on some occasion you have heard the term rheology, with which most of us who are dedicated to the transformation of plastic are not familiar. However, it is important that we understand some concepts in this topic to relate the phenomena that happen to plastics when we process them.
The polymeric rheology is the study of the flow of the material mainly liquid, but also the deformation of the solid state in respons e to an applied force.
What is viscosity?
Plastic injection molding companies in USA say viscosity is opposition to flow, higher viscosity increases resistance to flow. Therefore, a plastic that exhibits a higher viscosity will have a greater resistance to flow. Water is a very easy flowing substance, therefore it is considered to have a low viscosity. Gases have even lower viscosity compared to water, therefore they flow even easier.
Other substances, such as honey, have high viscosities, which prevent them from flowing easily under normal circumstances. Viscosity depends on several factors and is an inherent property of the fluid but can be influenced by external forces.
What do you know about Newtonian fluid?
In a Newtonian fluid such as water, the viscosity remains constant and is only affected by pressure and temperature, its viscosity being independent of the shear rate. In non-Newtonian fluids such as plastic, the viscosity changes as a function of modifying the cutting speed, therefore, plastic injection molding companies in USA during their processing its viscosity will always be changing.
The viscosity of a polymer is influenced by its average molecular weight. A sample of polymers comes up of a mixture of homogeneous polymers with different chain lengths. Therefore, plastics determine an average molecular weight, which in turn has a direct relationship with the properties of the plastic.
The relationship between molecular weight and viscosity is relative, since there are often cases of incorporating fillers or additives in the plastic formulation without altering its molecular weight. "Viscosity is proportional to the molecular weight of a plastic and inversely proportional to its temperature and flow rate"
HOW TO DETERMINE THE DEGREE OF VISCOSITY OF A PLASTIC?
There are different methods common in plastic injection molding companies in USA to measure the viscosity of plastics. One of them is through a capillary rheometer, which characterizes the viscosity of the material. It comes in a wide range of cutting speeds and temperatures.
However, it is one of the least common methods by the industry due to the complexity of interpreting the data obtained. Another method to interpret the viscosity of a plastic is also famous. And with which most processors are familiar is through the Melt Flow Index (MFI) test performed with a plastometer. The MFI test was not intend to measure viscosity. People adopt it by the industry for this purpose.
The capillary viscometer or rheometer is a laboratory instrument. It is common to measure the rheological properties of a plastic. Moreover, it comes in a wide range of cutting speeds and temperatures in plastic injection molding companies in USA, which resemble the conditions in which a plastic will be exposed during the injection molding process.
WHAT IS MFI TEST?
The MFI test will sound familiar to plastic injection molding companies in USA. Since it consists of introducing pellets into a cylinder. It heats to a particular temperature. The molten material comes to pass through a nozzle with a hole of known diameter. The force common for this action comes through a weight.
How do we show the result in plastic injection molding?
The test method standardizes under ISO 1133. The result we record comes on how many grams of plastic came out of the nozzle in a 10 minute period. Therefore, the units common for the test give in "grams / 10 minutes".
There is a relative relationship between the MFI and the molecular weight of the plastic. MFI values are inversely proportional to molecular weight. The higher the melt index, the lower the molecular weight. However, there are many other factors that can alter this relationship and make interpretation difficult.
Reduce or eliminate many production problems and defects by selecting the appropriate China plastic injection molding. For more complex designs, use the Moldflow Injection Threshold Suitability Analysis to determine the optimal injection point location. Moreover, it happens from a range of recommended locations. These all operations need professional injection molding team.
The way molten plastic polymer flows through a mold can have a big impact on the quality of a part. Similarly, use the Fill Preview tool to test different injection point locations and get a preview of the mold fill.
Some dominant Properties of thermoplastic injection molding
Compare the properties of different plastics and China plastic injection molding and get recommendations for molding and processing conditions, regardless of the materials selected.
Similarly, thermoplastics and thermosets are the two main types of plastics used in manufacturing. In addition, they have different properties and are suitable for different applications.
What molding defects can you find out?
Simulate how parts are filled early in the design process to reduce mold defects, retooling, and design changes. Identify where defects will occur and how you can modify your design or molding conditions to reduce or eliminate them.
What are the properties China plastic injection molding materials
Generally, it performs structural analysis tests to verify critical loads. Furthermore, the injection molding process affects the structural properties of the product.
If the product of China plastic injection molding is under a critical load case, you can perform a structural analysis test in the injection molding process to include it in the analysis.
How Visualization of fault is possible?
Simulate the injection molding process to understand how part geometry, injection point location and molding process affect visual defects after shrinkage and warpage pieces.
Optimize the position of injection points, part geometry, and the molding process to reduce defects in the most visible areas. You can export the position and depth of sinkers in.
China plastic injection molding use Moldflow software to reduce optical quality issues. These can be blurring or double images. Different factors influence birefringence, including material, mold design, and molding conditions. Moreover, it can be anticipate optical performance issues in plastics.
Unidirectional nucleus displacements
Similarly, examine the pressure difference around the core that is likely to cause the core to deflect, and use unidirectional stress to aid your analysis.
Basically, plastic injection is a process based on the design of a stainless-steel mold. Moreover, for perfect and flawless parts, the mold must therefore be made with the greatest care by experienced professionals.
How to recognized professionals in plastic molding
A project including parts from plastic molding requires contacting competent and qualified professionals.
Plastic injection is a highly technical and complex task. For flawless parts, you must contact a qualified company with proven know-how and experience.
How professionals China plastic injection molding companies meet customer demands?
These professionals know the constraints of each profession and respond perfectly to the demands and needs of their customers, even when the standards are drastic such as for the medical or the army.
Whatever your project and the type of plastic part drawn in the series you need, China plastic injection molding will accompany you from the design to the realization of your injected plastic parts.
What to do after having quality final parts?
To have quality final parts, you will need to call on a company with a dynamic team that can advise you and finds tailor-made solutions for the realization of your project. It will have to assure you of finished parts of high quality.
Their technical team must be efficient in the development of your molds, but also in the plastic injection process.
The parts must come off the line without error, with irreproachable precision while avoiding confusion. Some specialized companies offer a specific prototyping method called stereolithography for the production of parts in small or large series.
Is China plastic injection molding quick?
The technique of China plastic injection molding is very fast, on the other hand, it will be necessary to inform yourself well about the quality of the materials used. Preferably, it is always advisable to work with a subcontractor specializing in plastic injection.
Choose a partner who knows your field of activity!
Before choosing a partner for your plastic injection project, you must first find out about his professional experience and his specialty. Medical, agrifood, industrial… in which sector of activity does it operate?
He must be able to present you with quality molds, made to measure, capable of perfectly meeting your requirements and expectations.
How molding parts are recognized and qualified in the field of plastic injection?
China plastic injection molding is recognized and qualified in the field of plastic injection is often successful in 3D printing. Remember to check if the polymer injection molding company you want to choose also masters modeling CAD / CAM techniques.
Generally, it must be able to take charge of all types of projects related to its activity. If it has a website, do not hesitate to consult it to view its achievements as well as the various services it offers. Ask for samples!
Make comparisons to benefit from China plastic injection molding
Request quotes from multiple companies and compares them. A good partner for plastic injection must be able to meet the commitments it has made and the specifications.
He must know how to associate you with all stages of production and wait for your validation at each stage. Prices of China plastic injection molding parts is vary depending on the equipment used for the design and the fineness of the parts you want to obtain.
You should not, therefore, limit your choice to a question of budget, also consider the quality of the services offered to you
Among engineering plastics and plastic molding for china, resins that have cavity surface temperatures above 100°C are gradually increasing. If the surface temperature of the cavity is above 90°C, it is normally difficult for us to increase the temperature if we perform temperature control using hot water.
In general, the following plastic molding for china methods are common
(1) Oil temperature control
In oil temperature control, oil comes from a circulation pump by a hose through a passage designed inside the mold plate and the casting cavity, thereby maintaining a constant temperature. Once this temperature rises to the set temperature, we can maintain a relatively constant temperature.
However, the disadvantage of this method is that it takes time for the temperature to rise. Moreover, it can also cause burns hazard to people while handling the oil, and there is also the problem of waste oil disposal later.
(2) Electric heater: plastic molding for china
In the process of temperature control using an electric heater (cartridge heater), the temperature comes constant using this heater in combination with a temperature sensor (temperature pair...). Due to its high heat capacity, it has the advantage of rapid temperature rise. We use this technique in plastic molding for china.
However, the temperature near the heater will be high and the temperature far away from the heater will be low and thus it is difficult to maintain a uniform temperature distribution.
In addition, because the heater has a limited lifespan, it is also necessary to replace it periodically.
Mounting Heater to Control temperature
Mounting holes and clearances will be important while mounting the heater. If the clearance is too large, the heater will be in idle operation and therefore its life will be shortened.
In order to realize precise temperature control, we need to put an insulation plate between the plate of the injection machine and the plate of the mold mounting plate. Or it is also possible to design insulation panels around the mold.
In the case of plastic molding for china, since this resin needs to maintain the mold cavity temperature at more than 100°C, temperature control using oil or temperature control using a heater will be necessary. The temperature control method commonly common by commercially available heaters is the ON-OFF control method. We control the temperature by turning on or off the power to the heater.
Since the ON-OFF control method is easy to do with a simple switching device. Although the cost of this type of controller is relatively low. The fluctuations in the cavity surface temperature will become large. And therefore its disadvantage is that it is difficult to stabilize the temperature.
If the cavity surface temperature is not stable, it will cause fluctuations in material shrinkage, dimensions and surface gloss in precision molded products.
What is plastic molding for china PID method?
PID plastic molding for china control is a control method that can shorten the time we require for the temperature. It is to become stable by controlling using the following types:
- Differential (Derivative)
The heater can have a maximum load of 10kW with 200V three-phase AC. Therefore, as a usage example, we can take two 200V 1kW three-phase heaters and integrate them in the dynamic side mold plate and the stationary side dies plate, and performs a stable control of the surface temperature. casting cavity surface using PID control method.
Insulation panels are important to stabilize the temperature of plastic molding for china, or to save energy while maintaining the temperature. They are common as a mandatory part in the injection molding of engineering plastics or super engineering plastics.
In general, the method of using insulation panels can be of the following two types.
- Common by fixing to the plate of the plastic injection machine.
- Common by fixing behind the mold mounting plate
During the thermoplastic molding process, we can obtain the molded product of the desired size by using shrinkage when molding. Casting shrinkage is a phenomenon in which the volume of molten plastic filling the inside of the mold shrinks when it is cooled and solidified.
The extension of this plastic molding for china shrinkage is known as the “casting shrinkage”. And it is precisely known from experience and experiment. By designing the mold with the size of the casting cavity larger by an amount equal to the shrinkage, we can shape the molded product so that it has the desired size.
The value of the shrinkage factor is usually a number between 2/1000 and 20/1000 (range from 0.2% to 2%).
If the shrinkage factor is represented by the symbol α (alpha), then it is easy to define by Equation 1.
α = (L0 − L) L0
If further considered, the coefficient of shrinkage affects by the following factors:
1. Type of casting material for plastic molding for china
The range of the basic shrinkage factor comes by the type of plastic material common. However, it also varies according to the plastic molding for china and the quality class of the material.
- Mold cavity surface temperature
The molding shrinkage coefficient varies according to the cavity surface temperature during the plastic injection process. In general, the coefficient of shrinkage tends to be large if the temperature is high.
- Holding pressure x pressure holding time
The shrinkage coefficient varies according to the magnitude of the holding pressure after the resin injects and the time that the pressure maintains. In general, the shrinkage coefficient tends to be smaller when the holding pressure is high and the holding time is long.
- Wall thickness of molded product
The shrinkage factor also varies according to the wall thickness of the molded product. It tends to be larger if the wall thickness is larger.
5. Cast gate shape plastic molding for china
The aspect ratio varies according to the shape and size of the plastic molding for china casting gate. In general, it tends to decrease as the cross-sectional area of work becomes large. In addition, the aspect ratio also tends to be smaller in the side gate type than in the pinpoint gate or the submarine gate.
- Presence or absence of filler material into the casting material
Usually, there will be a large difference in the coefficient of shrinkage between natural materials and materials with glass fibers. The coefficient of shrinkage tends to be smaller in the case of fiberglass materials. In practice, the shrinkage factor for mold design is determined by exhaustively studying the above conditions.
After the third industrial revolution and the advent of electronics, computers and telecommunications, a new upheaval in our industries is taking place. Moreover, discover the challenges of Industry 4.0 and how the world of china plastic molding is adapting to these changes.
What is Industry 4.0 plastic molding?
The concept of Industry 4.0 first appeared in 2011 at the World Industry Forum in Hanover. Furthermore, this international project, also known as the “industry of the future”, was thus launched with the aim of revolutionizing the means of production to meet the needs of tomorrow.
Connected objects and industrial internet network
Autonomous sensors are the main tools for the transition to intelligent production systems. Similarly, they allow china plastic molding to diagnose problems by collecting data remotely on an autonomous basis. We think for example of RJG pressure sensors.
Big Data, Cloud and Industry
Massive data collection by industries involves “Big Data” management and cloud use. Transparency of information with customers is therefore synonymous with trust.
Cyber-physical systems for china plastic molding
The new automation revolution is now based on “cyber-systems”, complex systems that communicate continuously with their environment. This permanent interaction between machines is made possible by the combination of computer, physical and advanced communication systems. China plastic molding Production management is improved through predictive maintenance.
Modern industrial robots are no longer designed to stupidly perform frozen and automatic operations. In addition, they are now collaborative and intelligent, that is to say, they are able to assist operators and technicians in real time and free them from their most arduous tasks.
Furthermore, Cobotics can thus take the form of collaborative robotic islands, mobile robots or even exoskeletons.
Challenges and perspectives of the china plastic molding industry
The factory 4.0 is a response to new requirements which translate into new challenges for companies in terms of market development, technologies, but also at the level of organizations, the environment and even in terms of societal.
Productivity gain and personalization
Mass product customization is one of the main challenges of Industry 4.0. The use of new technologies thus makes it possible to remain competitive, productive and localized in France.
Ergonomics of interfaces and software
To gain in efficiency and china plastic molding productivity, Industry 4.0 must equip itself with tools that simplify the task of operators as much as possible. Thus, the ergonomics of the interaction between robots, machines and users must be integrated from the design phase.
This ease of use is found at all levels: programming software, augmented reality applications, robot interfaces, any application must be designed to save time while remaining flexible and configurable.
Thanks to artificial intelligence, Industry 4.0 integrates smarter systems capable of evaluating and correcting themselves.
How china plastic molding fits into Industry 4.0?
Injection molding comes at the heart of the plastics industry competitiveness cluster. Thanks to this environment conducive to innovation, this plastic injection specialist makes every effort to be at the cutting edge of technology and constantly invests in the training of its employees and the transmission of its know-how. Therefore, the mindset of china plastic molding is fully compatible with Factory 4.0.
A 4.0 technological offer
We develop complex industrial islands and has the capacity to create added value through sustained technological investment. Concretely, this translates into strong automation, by the presence of sensors capable of monitoring production, on 100% electric machines.
In the world of Industry 4.0, companies must have agile management of their processes. This flexibility takes the form of constant evolution and adaptation according to customer needs and the emergence of new technologies.
In order to always stay "up to date", we seek to surround itself with the best, through the development of strategic partnerships in all areas: injection machines, production peripherals, cobots, and measurement and sensor systems. …Furthermore, nothing is left to chance!
A human-oriented organization
Generally, putting people back at the center of the company is one of the challenges of the Factory of the Future. Similarly, China plastic molding is particularly sensitive to the transfer of knowledge and the preservation of knowledge.
On a daily basis, this sharing takes the form of continuous training of employees in new technologies and by monitoring changes in each profession.
Finally, we employ a multitude of profiles, as varied as they are complementary. Background, experience, gender, age: a wealth that benefits the needs of its customers.
Traceability of surface defects
Visualize the flow path of the polymer to identify conditions that could cause surface defects on the part. Identify the injection point through which the fluid particles entered, the distance traveled by these particles before freezing, and the path taken through complex geometry.
Induction heating: china plastic molding
Simulate the rapid heating of magnetic components in the mold by electromagnetic induction to achieve a high quality surface finish with no visible weld lines.
Controlled opening of the nozzles
Improve the quality of surface finishes with speed controlled opening and closing of nozzles, combined with sequential nozzles. In addition, anticipate the effects of slow opening nozzles to avoid the effects of hesitation and surface defects.
Injection molding of thermoplastics
Simulate and evaluate your entire design and molding process by analyzing different variables from a large database of thermoplastics and a wide range of analysis results. Furthermore, China plastic molding tools allow you to simulate and optimize the injection molding process of thermoplastics for your application.
Shrinkage and warping
Simulate warping of the manufactured part to ensure a suitable and functional end product. Obtain precisely compensated models for tooling or for subsequent geometry changes.
In the event of excessive shrinkage and warping, you can easily isolate the underlying cause of the warp (differential shrinkage in the part, mold cooling imbalances or material orientation) and thus study the solutions and targeted actions that will resolve the problem. The china plastic molding database contains category-specific data to ensure the highest level of forecast accuracy.
Cooling of molds: china plastic molding
China plastic molding uses advanced cooling techniques and arrangements, including conformal cooling and transient heat calculations. Similarly, take advantage of the arrangement of cooling channels and the cooling process to create high quality products with short cycles.
Simulate advanced cooling technologies, such as rapid heating and cooling or conformal cooling. Evaluate the impact of highly conductive materials, heating elements and heat pipes on cycle time and product quality.
The plastic mold maker makes it possible to manufacture parts of complex shape in a single operation, very quickly. It is the ideal solution for quality production, in very large series and suitable for all sectors of activity, even the most specialized. Moreover, this industrialization is prepared from the design of the parts and requires real expertise. In addition, here are our tips for successfully industrializing your plastic parts.
Start on a solid basis with the pre-study
Plastic injection is a flexible and economical solution allowing the production of medium or large series. To succeed in industrialization, it is preferable to study the design and the necessary materials beforehand. Clearly, you will need to have precise and realistic specifications. Furthermore, you have to have a good understanding of the project and be able to make the right decision.
How do plastic mold maker develop design?
It is at this stage that plastic mold maker will think about style, ergonomics and the search for aesthetic forms. 3D CAD modeling is an essential tool here.
Functional analysis is at the heart of the preliminary study, because it conditions the choice of materials and the design of the part. This is a prerequisite for carrying out mechanical studies.
The study phase is completed by rapid prototyping, allowing having a realistic rendering of the project within 48 hours.
The choice of plastic mold maker materials
There is currently an extremely wide range of thermoplastic polymers available, each with specific properties: mechanical resistance, color, resistance to UV radiation, impact resistance, cost of the material, etc. Furthermore, it is therefore the use of the room that will largely determine this choice.
Design well for successful industrialization
A successful industrialization is above all a well-studied part, because everything prepares from the design stage.
Adapt the shapes to the injection process
Like any industrial process, thermoplastic injection has its own specific requirements and constraints. Thus, some basic rules plastic mold maker must respect:
• Sharp angles we need to avoid, because they concentrate the stresses and often generate deformations on cooling;
• The thickness of the plastic parts must be as uniform as possible. Each variation in thickness can cause too much shrinkage and aesthetic defects (shrinkage);
• Add drafts to facilitate the release of parts;
• Rib your parts to add rigidity without increasing thicknesses.
Anticipate production problems for plastic mold maker
Modern CAD software has modules dedicated to plastic injection simulation. The simulation makes it possible to predict certain defects on the plastic parts before the manufacture of the mold launches.
Weld lines, air inclusions, warping or even shrinkage, all these defects are thus predictable and avoidable for plastic mold maker. In addition, digital simulation software is able to analyze the mechanical resistance of parts (RDM) and study the flow of plastic (rheology).
Molds adapted to your needs
Thermoplastic injection requires the manufacture of molds which are the centerpiece of the process. Moreover, each mold is a custom-made tool, which corresponds to your production needs.
The mold is an investment that comes over the life of the product. The quality of the steels that comes according to the life cycle of the product, and also the number of borrowings compared to the quantity produces.
The qualities of a good plastic mold maker
To successfully industrialize your plastic parts, you will first need to find the right industrial partner.
The production of quality parts, that is to say with beautiful surfaces and which does not deform during injection. It requires years of practice for plastic mold maker. Consequently, the industrial partner with a great deal of business experience will be the one who will know how to design flawless molds.
Above all, you can rely on its expertise with your eyes closed and let yourself be guided for optimized design and production. Finally, a partner who carries out tests in real conditions after the mold develops is also a guarantee of confidence in order to avoid any unpleasant surprises when production is launched.
The use of advanced technologies
CAD and digital simulation are not the only cutting-edge technologies available to plastic injection professionals. Before starting the manufacture of a production mold, it is advisable to go through a rapid prototyping step in order to validate the conformity of the product with respect to the specifications.
Rapid prototyping, also called “3D prints”, is now one of the technologies that are revolutionizing the world of industrial manufacturing on a daily basis. Therefore, for the manufacture of your parts, choose an experienced and reliable agile plastic mold maker. This will guarantee you a quality production and a stable process.
A good plastic mold maker clears his Project Vision
The key notion to remember is that of “partner”, committed to the project and who has a 360 ° vision of it. If the injectors obviously master the injection, the difference lies in the commitment to follow the overall project in the direction of the customer.
A commitment that will make it possible to find solutions to respond to each problem, to find the right partners, always with a view to being as close as possible to the customer's wishes.
Always faster, cheaper and better
These are the challenges to which mold makers must now respond. A nice challenge you will tell us, especially as plastic injection-molded parts are more and more complex. It is to produce, and the allocated development times are shortening.
Antinomic? Not necessarily. Discover how rheology associated with computer-aided design / manufacturing (CAD / CAM) enables plastic mold maker. It is to gain efficiency and productivity while striving for excellence.
How to simulate the filling of a mold?
First and foremost, it is important to understand the mechanical behavior of the material used. It is in order to define the characteristics of the mold, design recommendations, and the manufacturing method.
How does the material flow in the tooling cavities under plastic mold maker? What are the relationships between its viscosity, plasticity and elasticity? How does it deform under the influence of stresses, such as pressure for example?
As you will have understood, it is a question here of resorting to rheology. As a reminder, this science studies the deformations and flow of materials. It is to model their behavior, according to very precise factors and physical data. It is essential to the plastics industry.
The fundamentals of plastic injection
Design a part of constant thickness to limit its deformation and internal stresses during post-injection cooling is something must for plastic injection molding companies.
Define a parting line to determine the part's demolding direction;
Define drafts to ensure good ejection of the part when it comes out of the mold. The draft designates the angle that is given to a surface so that it can be released from the mold.
Conversely, generating undercut consists in designing a shape that goes against the mold release for technical reasons, for example the realization of specific technical functions such as clips.
Plastic injection molding constraints and functions
Molding constraints can influence 2 categories of functions:
- Technical functions
As plastic injection is a means of obtaining which, by definition, makes it possible to design thin (shells) and demouldable parts, not all parts can be produced in this way.
This therefore implies the presence of undercuts to allow demoulding and the absence of undercuts preventing demolding .
The production of plastic injection molding companies is sometimes possible, but it requires providing additional functions to the mold, which increases the cost of the tooling. In this context, the definition of certain technical functions must be carried out in correlation with the means of obtaining … and the validation of the mold maker.
How to enhance plastic injection molding companies development phase?
It is important to always anticipate the development phase of the mold and to define the geometry of the part in the direction of retouching of the latter. It will always be better to machine the mold than to have to add material to “reload” the mold.
The development of a clip is an example of the development. It is recommended to orient you on a clip with a “weaker” stiffness, in order to “stiffen” it when focusing.
Moreover, this method of obtaining inevitably generates more or less significant deformations on the final part. The level of geometrical precision is obviously not as important as in the case of the machining of a metal part for example ... This is why, here again, it is important to identify the functional constraints potentially impacted upstream of design in order to implement modifications to limit them.
Aesthetic functions of plastic injection molding companies
The main impacts of molding constraints are aesthetic:
- Traces of injection points,
- Shrinkage (materials contract on cooling; however, the thickest areas tend to contract more than those of low thickness),
- Ejector brands,
- Streak marks,
- Welding lines,
- Textured shading,
- Non-uniform color ...
The origin of these defects is varied in plastic injection molding companies. They may result from the design of the injection mold and the molding conditions.
The challenge is that many plastic parts are trim parts, the main function of which is precisely the aesthetic function.
This is why to work on the cosmetic aspect of these parts, it is extremely important to integrate these constraints upstream of the project, during the design of the part. It is then necessary to define the material, the thicknesses, the undercuts, the parting line ...
Plastic injection molding graining
For example, the injection process makes it possible to produce a texture which is called “ graining ”. Even if this operation is carried out in the mold after geometric validation of the part, it requires a specific angle depending on the depth of the grain. Therefore, this draft angle will have to be taken into account well upstream of the design.
Again, at this stage, collaboration with the plastic injection molding companies is very profitable because the information and advice gathered often saves time and money.
A double challenge for the plastic injection molding companies of the Design Office
Within the AMETRA Group, the work of the engineers in the design office will therefore have to combine a functional reasoning (the parts must carry out X and Y technical functions) with a reflection on the aesthetic rendering.
In aeronautics and the automotive industry, for example, plastic parts are often associated with trim. They are seen by the end-user, so their appearance is inevitable.
What is plastic injection molding companies bad design?
A bad plastic injection molding companies design can generate many aesthetic defects, it is important to use our know-how very early in order to make sure that everything goes well during the manufacture of the plastic part, which will go through physical phenomena of changes. state ultimately having a very significant impact on its rendering.
Problem of burn points on the injected part.
Possible causes can be:
- - Clogged gas leaks.
- - Injection speed too high.
- - The material temperature is too high.
- - Clean up gas leaks.
- - Reduce the injection speed.
- - Reduce the temperature of the material.
Problem of spontaneous burrs in the assembly areas.
Possible causes can be:
- - Foreign body in the parting line.
- - On injection of the part.
- Similarly, the material temperature is too high.
- Moreover, the machine does not have sufficient closing force to compensate for the injection pressure.
- - Control of the mold cooling temperature
- - Checking the adjustment zones makes it possible to check that no foreign element has been introduced or that there are no plastic residues from previous injections.
- - Checking the surfaces of the partition to detect any damage.
- Furthermore, check the injection process: speeds, temperatures, load and pressures.
- - Regulation of the closing force of the machine.
- In addition, check the cooling of the mold.
Continuous burrs in the adjustment areas.
Possible causes can be:
- - Wear of the adjustment zones.
- - Foreign bodies or plastic residues deposited on the seals.
- - Machine chucks out of adjustment.
- Moreover, incorrect injection parameters: speeds, load and pressures.
- Similarly, the material temperature is too high.
- - The solutions :
- - Repair the gaskets and readjust the injection mold.
- - Remove any foreign objects or plastic debris in the clamping area.
- Similarly, Repair the gaskets and readjust the injection mold.
- - Review of the injection process: speeds, temperatures, loads and pressures.
- In addition, Regulation of the closing force of the machine.
- - Check the cooling of the mold.
Possible causes can be:
- - Plastic temperature too low.
- - The material entries section is different.
- - Injection points blocked.
- - Non-uniform heating of the hot runner.
- Furthermore, Nozzles at different temperatures.
- In addition, Unequal evacuation of gases due to leaks.
- - Lack of uniformity in cooling.
- - Checking the injection temperatures.
- - Check the condition of the injection nozzles.
- - Moreover, Check the operation of the shutters.
- - Check the resistances of the hot runners.
- -Similarly, Check for gas leaks.
- - Check the cooling of the mold.
To take into account the plastic injection molding companies constraints from the design of the part, there are several solutions. Either we have significant experience feedback, or we are able to involve the company which will produce the mold later. Unfortunately, the mold maker is not always known and chosen from the start by the customer for whom the part is designed.
Among the techniques for the transformation of plastic materials, the most widespread is custom plastic injection molding.
In this industrial production process, the plastic material is melted (plasticized) and injected at high pressure into a closed mold.
The Advantages of This Type of Processing Are:
- high productivity
- low production costs, given the high automation of processes
- possibility of producing parts with complex geometries, very small, but also very large
- Production of products with different colors and materials.
Like professional custom plastic injection molding companies, we also deal with this plastic processing technique: our factory boasts an efficient and complete fleet of presses equipped with manipulator robots with a clamping force of up to 1,800 tons , to print even large items.
We provide Greater custom plastic injection molding Technologies
In addition, in our production department of over 2,500 square meters we also carry out over- injection and molding with nitrogen, a gas that allows us to quickly create hollow objects internally.
Plastic extrusion: characteristics and potential
L ' extrusion is a plastics processing technique which allows the creation of a constant section products (called "extruded") such as pipes, rods, plates and various plastic sections type.
Its characteristic is to create objects of great versatility.
The extrusion technique is good to use with metallic materials (such as steel, aluminum, lead, or copper), plastics and in general with materials that have high plasticity. The types of plastics that can be used are diverse, including PVC, PE, PP and PA, as well as rubber.
How does extrusion work?
In this technique, the material, which must be pasty, comes to pass by compression through a shape ("matrix" or "die").
- the plastic material, in the form of small granules, is heated and then melted
- then the shape is given by compression through the matrix
- the plastic is finally subjected to a cooling-consolidation process.
What professional custom plastic injection molding offers?
Extrusion is certainly one of the most used techniques in our factories, to obtain products with constant thicknesses and with great versatility of application.
In particular, we can make sheets with thicknesses that can vary from a few millimeters to a few centimeters and rounds from a minimum diameter of 20mm to a maximum of 300mm.
The importance of finishing in plastic processing
The custom plastic injection molding process is not possible to complete until the finishing touches give with the finishing process.
The finishing of plastic articles is in fact fundamental for the quality of the articles, both in terms of performance and aesthetics.
Each year at our company we process more than 16,000 tons of plastic material. Let's find out together how the objects produced in our factory.
The assembly of the articles takes place directly in our production department to offer a faster and more flexible service. Being made directly by us, we have direct control over every phase of the process, thus guaranteeing further precision and accuracy.
The heat sealing is the ideal technique for all the welds of the watertight plastic, even for large parts. It also allows you to make three-dimensional welds or internal walls, even thin or complex shapes. There are many advantages, such as high quality in terms of resistance and hermetic seal, and time savings.
Custom plastic injection molding Labeling
In addition, custom plastic injection molding allows you to optimally print high-resolution images.
Thanks to our automatic labeling line we can apply self-adhesive labels from reels with a maximum diameter of 280 mm.
In addition to welding and labeling, we finally make high-precision cuts thanks to the aid of 6-axis anthropomorphic robots that simulate the movements of the human arm, reducing time and ensuring high precision.
The blow molding technique is a production process used to obtain hollow plastic products, such as bottles or flacons.
With this technique it is possible to obtain objects - even with thin thicknesses - for mass production, thus reducing costs.
How does custom plastic injection molding work?
The process is simple and intuitive:
- a plastic preformcomes inside a special mold
- compressed airblows into the mold from the outside , so that the preform adheres to the walls of the mold
- The object is then cooled and the mold opens, thus releasing the finished product.
What we offer for blow molding?
Blow molding is one of the plastic molding techniques that we most use for the processes requested by our customers.
What do you get?
- Completed project on time.
- Mold made in accordance with the statement of work.
- A quality end product.
- Nice pricing policy.
The cost of custom plastic injection molding depends on:
- terms for development;
- additional design features of the mold;
- the need for subsequent manual processing;
- special requirements for the project.
Injection molding of plastics: stages
- Design and 3D modeling of the mold is developed based on finished data or using a finished product.
- Manufacturing of a mold for plastic injection based on a 3D model.
- Test casting to check the correct geometry of the product and conformity of the mold to the TOR.
- Modification of the mold in case of identification of defects.
- Delivery of the project to the customer.
What is the main advantage of custom plastic injection molding?
The main advantage of custom plastic injection molding is a very short production time. After creating a 3D model, and the use of materials with different properties, you can proceed easily. At the same time, the products do not have external differences and fully correspond to products.
Why custom plastic injection molding techniques is suitable?
Custom plastic injection molding is suitable for testing the technology. The surface texture depends on the prototype's 3D printing technology. Accordingly, if you want to get the quality after the injection molding machine, then you need to refine the prototype. In most cases, this is manual labor and to reduce it, we use stereolithography technology in 3D printing prototypes.
How many cycles does a 3D-printed mold withstand?
Below you can see that 3D printed forms can withstand a sufficient number of cycles to produce small batches of goods. This is quite inspiring information, because small-scale production has always been costly and troublesome.
Traditional metal molds are expensive and depend on long-term supplies. And this significantly affects the cost of small-batch products. The use of the custom plastic injection molding for printing molds significantly reduces time and material costs.
What does "3D printing" mean?
Plastic injection molding parts 3D printing brings a lot of opportunities in various industries. They can bring to life the craziest and most original ideas. This applies not only to mass-produced products, but to individual ones. With the help of modern technologies, you do not need to manually make each copy; you can significantly speed up the process.
Plastic injection molding parts Bring Great Opportunities to Various industries
You can order figurines of your favorite characters from precious metals, create objects of unusual shapes for the interior.
The use of 3D printing is used in many industries, but it is important for jewelry also because it eliminates the costs associated with the loss of precious metals. Any errors associated with gold are too costly.
Benefits of plastic injection molding parts
The use of plastic injection molding parts with 3D printing is a turning point in jewelry, as this approach allows you to optimize production with many advantages:
- Thanks to the use of 3D printing services, you can create real works of art, jewelry of a very complex shape, with an abundance of small details. The printing wax layer is up to 16 microns thick.
- 3D printing allows you to create prototypes of jewelry, molds for further equipment from wax. Also, this method is suitable for obtaining master models for investment casting.
Methods and stages of prototyping
Before 3D printing a prototype, it is good to create it in a special program on a computer. It is the use of a 3D printer that is the most popular and affordable way to create prototypes.
Another way to create a prototype is 3D milling. This method also allows you to create a prototype of any complexity, but it will take more time than using a 3D printer.
The main stages of plastic injection molding parts prototyping include:
- Model preparation. To do this, you will need to use special software that allows you to make a 3D model.
- Model creation. The main stage of prototyping.
Technology features of plastic injection molding parts
Prototyping and plastic injection molding parts 3D printing of objects is a procedure for creating an object based on special devices. Most often, a 3D printer is used for prototyping, which allows you to print a product quickly and inexpensively. This is due to the minimal use of consumables and the low cost of the raw materials used.
Printing is carried out from the bottom layer, gradually printing all layers. The result will be a volumetric prototype of the future product, on the basis of which it is possible to understand the main mistakes and make adjustments before the product is sent to mass production.
Sphere of using 3D modeling and prototyping
Prototyping of various objects is used in different fields of activity:
- Manufacturing a prototype of an object before releasing it into serial production. This will allow you to identify all problems, estimate the size, weight and other characteristics of the product and, if possible, correct the deficiencies even before the product is released into mass production.
- Printing layouts for demonstration to the customer or potential clients of future objects. This will make the advertising campaign more visual.
- Printing of test samples of products. If it sways individual parts, then they should go up to the main object. Testing a prototype product will allow you to identify any flaws and make adjustments.
- Production of objects in different colors and scales in order to choose the best option that will be used in serial production.
Plastic injection molding parts is an ideal solution for Prototyping
Plastic injection molding parts and prototyping is the ideal solution for quickly and cheaply creating a sample of products before launching them into mass production.
Thanks to high precision and detailing, the finished prototype will be the most visual example of the product. And the shorter print times and affordable manufacturing costs make 3D printing ubiquitous.
Are you looking for a manufacturer of plastic housings for the electrical industry? If the housings are not electrically conductive but need to have an attractive color or finish, plastic housings are excellent. Since plastic is very easy to process, very short production times can be achieved.
We manufacture high quality customer-specific plastic parts
Plastic housings, in particular injection molded housings, offer a multitude of design options. Sophisticated design, low weight and sophisticated optics can be implemented optimally.
Various textures are possible in plastic injection molding parts:
- Multi-colored details
- Combination of hard and soft
- Grit for areas that are easy to touch
- Marbling effects
- Cast inserts for threaded bushes
With a wide variety of plastics and processing technologies, your design is practically unlimited.
We manufacture plastic housings according to your ideas, including displays, seals, membrane keypads, battery contacts and control panels - coordinated and assembled.
Have plastic housings milled: when is it worth it?
Expensive casting tools are of lesser value, especially for very specific products that are not too large in quantity. If the batch size of complex housings is around 30 to 40 pieces per month, it makes sense to contact specialists.
In addition, we can more easily produce complex fits that are very difficult to achieve due to shrinkage and warpage in various casting processes.
The process of plastic injection molding parts usually looks like this:
You send us your ideas or requirements, images and existing 3D product data
If the project of the case has not yet been developed, we will design your custom plastic case and send you 3D presentations, drafts and technical drawings
After your approval, we will manufacture the plastic housing, including surface treatment and markings
Since the surface of the plastic can be coated and marked, we would be happy to advise you on the right coating and laser marking.
Plastic housing manufacturer: tailor-made solutions
In industry or for fast-moving consumer goods, high demands often take place on housings. Expensive and complex casting tools are less profitable, especially with extremely high quality products in slightly smaller quantities. We are expert in plastic injection molding parts - from design to series production.