A Comprehensive Guide on plastic injection molding with Hydraulic Machines
Hydraulic plastic injection machine
Hydraulic mold clamping machine
The hydraulic mold clamping machine is a plastic injection machine that uses a hydraulic system to open and close the mold and maintain that clamping force.
The hydraulic system also makes the screw rotate, move back and forth and give force to the pushpin. This system includes a pump, valve, motor, pipeline, and oil tank. Etc.
Electric plastic injection machine
It is a plastic injection-based machine that uses a servo motor to adjust the mold opening, closing, and mold pliers, pushing the backing pin.
Some of these machines also come with a servo motor to control the back and forth movement of the screw. This machine does plastic injection molding. As far as I know, the electric plastic injection machine appeared on the market around 2005 in Japan.
The electric injection molding machine
A popular electric plastic injection machine on the market
Should you choose an electric plastic injection machine or a hydraulic plastic injection machine?
To give sincere and accurate advice in choosing an electric plastic injection machine or a hydraulic plastic injection machine is not easy. Each type of machine has its advantages and disadvantages.
Therefore, depending on the specific job, you can buy the appropriate plastic injection machine to bring the highest economic efficiency. Below I will compare these two lines of plastic injection molding machines according to the essential criteria so that readers can make the best decision.
About power consumption:
Electric plastic injection machines save you 20-40% of electricity consumption compared to hydraulic plastic injection machines. This is understandable because the hydraulic plastic injection machine uses a hydraulic system.
Construction of plastic injection molding
It includes pumps and motors to recycle hydraulic oil to supply the whole system even when there is no requirement. As for the plastic injection machine controlled by Servo motor, plastic injection molding only works and generates power loss when it is necessary to close, open the mold, and move the screw.
The hydraulic plastic injection molding machine has a faster opening and closing speed than the electric plastic injection machine because the efficiency of this type of motor at present has a lower rate.
How does plastic injection molding increase productivity?
Depending on the specific jobs is a disadvantage of the electric motor because if the opening and closing take too long, it will affect the injection molding cycle. However, if the products need a lot of time to cool, using an electric plastic injection machine is not a disadvantage. On the contrary, plastic injection molding will increase your productivity.
Electric plastic injection machines are not suitable for products that need considerable injection pressure and large mold clamping force. It is effortless to get bogged down with the parting surface.
A considerable advantage of the electric plastic injection machine is that there are no hydraulic pumps, pump motors, valves, pipes. Hence, it is much lighter and neater than the hydraulic plastic injection machine.
A typical plastic injection molding machine needs about 300 liters of hydraulic oil to operate, also a small cost. In addition, during operation, I found that the electric plastic injection machine operates more quietly than the hydraulic plastic injection machine.
About the price.
Electric plastic injection molding machine is a relatively new technology. Therefore, the cost for you to own this type of machine is also much higher than that of a hydraulic plastic injection machine.
Besides, if you need to buy an old machine, it is not easy to find a cheap electric plastic injection machine because the life of this machine is very high.
Injection molding machines China
In the market of plastic injection machines in China today, a hydraulic plastic injection machine priced from 1 million-1.3 million tons can run smoothly.
You have to spend 1.8 million-2 million tons to have the opportunity to own one—electric plastic injection machine. Making cheap plastic molds is often associated with poor quality – it is a thought ingrained in us.
Products and Services
When buying a cheap product or embroidering an affordable service, people often think of the quality of the product. Plastic injection molding service is cost-effective.
Making cheap plastic molds
However, when making cheap plastic molds, designers and builders know how to optimize improvements and optimize unnecessary costs. We can ultimately make a plastic mold at a low price but still ensure quality. Ensure the requirements that the customer wants.
Factors affecting the price of plastic mold making
One factor that customers are often interested in is how much it costs to make a plastic mold. In this regard, our Plastic Mold Factory would like to advise customers on the factors that determine the cost of a plastic injection product.
Accuracy: This is perhaps the most important factor driving up the price of mold making. A plastic product made with plastic injection molding with a size that requires accuracy of 0.01mm - 0.1mm will cost much more than a product that requires accuracy of 1mm or more.
Products requiring precise mold components
It can be understood as follows; “Products that need to be precise require more precise mold components. To be accurate, mold components require higher precision machining machines.
The more precise the machine, the higher the purchase value… all of these factors drives up the cost of the mold.” Product shape: The simpler the product, the easier it is to make and achieve its intended use.
Products with complex profiles in plastic injection molding
In contrast, for products with complex profiles such as undercuts, threaded products, products that need slides, products that require high gloss, etc.,
The mold structure will be complicated, and it will take a long time to design the mold and process mold. And we have tested many times. This process requires some not small expenses.
Injection molding Product volume:
The larger the product, the larger the mold it is simple rule. Therefore, as the mold material increases, the cost of the mold will also increase.
Above are the two main factors that determine the mold cost. However, if you make a mold, you can rest assured because you don't have to spend a lot of money to make a mold.
Final thoughts on plastic injection molding
In this article, I just mentioned some criteria for evaluation that are within the scope of my understanding.
Currently on the market, several hybrid machines combine the advantages of both of these plastic injection machines.
How can a plastic injection molding factory reduce molding parts cost?
Injection molding technology in Modern Era
Injection molding technology
It pushes and squeezes molten materials into an existing farming system called a mold system, then cooling for the liquid material to crystallize and bring the product out.
Such a cyclic process is called an injection molding cycle. The shorter the cycle, the lower the product cost. Therefore, in injection molding, people often calculate the price based on the cycle of injection molding.
Plastic mold system: What is a template?
The mold, also known as the mold, is the heart of injection molding technology. The mold is machined and shaped based on the desired product shape. Plastic injection molding factory provides injection molding products. These are shaped by the structure and form of the mold cavity (also known as the core of the mold, the hoe, etc.).
The mold consists of two main parts called the male mold and the female mold. In engineering language and mold manufacturing industry factories. People divide the mold into two parts; mold fixed part and mold movable part.
The fixed part (the female mold)
The fixed part (the female mold) is the part that is stationary during the whole injection molding process. This part is connected to the injection nozzle of the injection machine.
A plastic injection molding factory would inject plastic into the mold cavity. This part includes a fixed part side core, guide shaft, plastic pouring nozzle, fixed mold plate.
Movable part plastic injection mold ;
This part moves when the mold closes during an injection molding cycle. This part has the effect of extending the mold to take out the product and the runner, then pressing the mold closely. Moreover, the material does not leak out (create three socks) by pressure during the injection process.
In addition to the two main parts that make up the mold, some complex molds also have a sliding platform, a motor system (threading mold), a hydraulic system. A plastic injection molding factory would provide this movable part.
Patterns and life of plastic injection molding;
Most of the everyday items are produced by injection molding technology, from simple things like shoe soles to helmets, children's toys, mobile phone cases, candy boxes. Creating molded utensils saves time. It is possible to mass-produce the same in a short time.
Therefore, injection molding technology plays a vital role in daily life. But most of us don't care about the existence of this field.
Plastic injection mold industry
The plastic injection mold industry currently needs many design engineers, but universities have not yet met them. In a plastic injection molding factory, most of the people working in this field are retrained from mechanical engineers.
In the past, mold design faced many difficulties because there were few supporting industries; however, at present. In addition, the auxiliary mold industry is very developed, so the design and manufacture of molds do not require as much time and effort as before.
How to reduce the cost of making molds?
To reduce the cost of making molds, we must solve and improve the factors that affect the price of molds. If they are an experienced mold maker when they receive a request from a customer, they will:
In a plastic injection molding factory, upon receiving the customer's request, we will directly evaluate based on the technical requirements of the product and give the most accurate and reasonable size to reduce the price of plastic mold to the lowest level.
What to do if product shape is complicated.
If the product shape is too complicated, it is necessary to improve the product to simplify the product but still ensure the features and technical requirements of the product.
The volume of the product not only affects the mold cost but also affects the product cost. Many customers are requesting to make products with too thick walls. But it is not necessary for the plastic injection molding factory.
Thick molds overview
Thick mold walls are not necessarily sound; uneven wall thickness will cause difficulties in the injection molding process such as deformation, concave, shrinkage. Hence, mold makers need to calculate into reasonable products, make thinnest possible to ensure the best product price for the customer. And it at the same time keeps the mold cost down.
There are also several other factors such as the number of cores in a mold, 2-plate mold or core-changing mold, mold material. Therefore, when receiving a customer's request, it is necessary to research to reduce the cost to the lowest for customers. In addition, plastic injection molding factory provides these molds easily.
Features of Plastic injection machine
Plastic laminators are common to pressing and covering paper or photos to prevent water from sticking and keep the product new. In addition, the machine is also common to print on all materials.
The machine can laminate business cards, brochures, plastic cards. Learn more about plastic injection molding machines.
The machine is common in a plastic injection molding factory
- The compressor at about three to five minutes. Flexible temperature control.
- The machine has a maximum thickness of plastic sheet from 75 to 300 Mic.
- The device can keep the strength and newness of the paper for a long time.
- Moreover, with a compact, beautiful design, you can easily move and install and use it easily.
- Similarly, the machine is also very easy to use; you just need to plug-in power and turn the knob to adjust the temperature.
- Furthermore, current status of plastic injection machines on the market
Plastic laminator usage in plastic injection molding factory
Plastic injection molding factory protects your articles with plastic coating. And this incorporation would help in giving you an improved form of the product. It would be a user-friendly plastic injection molding machine with outstanding reliability.
Plastic injection molding factory
Plastic injection molding machine features will create a thin coating, making the pressing happen quickly and easily.
To choose simple, high-quality machines, customers need to pay attention to their user’s needs. For example, notice how often you move? If you drive a lot, you should choose light, simple, and easy to use.
Custom plastic molding company: Learn How to control molding pressure?
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.
Tri state plastic molding company: How to program the turning speed?
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.
Plastic injection molding companies in USA: How to control throat temperature?
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.
How do China plastic injection molding companies use mold flow software?
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
Plastic Molding for China: 6 Factors that can Impact Mold Result
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.
How does industry 4.0 help in china plastic molding?
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.
Top 5 Qualities of Professional Plastic Mold Maker
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.
Plastic Injection Molding Companies: 3 Fundamental Rules for Molding
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.