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,
• Burrs,
• Burns,
• Deformation,
• 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.

Solutions:

• - 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

Solutions:

• - 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 :

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.

Solutions:

• - 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.

Summary

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").

1. the plastic material, in the form of small granules, is heated and then melted
2. then the shape is given by compression through the matrix
3. 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

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.

Hot welding

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.

Automated cutting

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:

1. a plastic preformcomes inside a special mold
2. compressed airblows into the mold from the outside , so that the preform adheres to the walls of the mold
3. 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?

1. Completed project on time.
2. Mold made in accordance with the statement of work.
3. A quality end product.
4. 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

1. Design and 3D modeling of the mold is developed based on finished data or using a finished product.
2. Manufacturing of a mold for plastic injection based on a 3D model.
3. Test casting to check the correct geometry of the product and conformity of the mold to the TOR.
4. Modification of the mold in case of identification of defects.
5. 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:

1. 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.
2. 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:

1. Model preparation. To do this, you will need to use special software that allows you to make a 3D model.
2. 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:

1. 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.
2. Printing layouts for demonstration to the customer or potential clients of future objects. This will make the advertising campaign more visual.
3. 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.
4. 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.  

Plastic injection molding service is a processing technique whereby thermoplastic polymers are melted and injected under high pressure inside a mold. This process takes place in order to produce a finished object or a plastic component. 

We are providing our services in both the production of precision molds and the injection molding of plastic materials for high, medium, low and niche production volumes.

Definition of Injection Molding

It is a forming process that uses molds. Specifically, in the injection molding of plastic materials, thermoplastic polymers heat up. We melt and inject them into a mold. Similarly, here, inside which they cool and harden, taking on the designed shape.

Injection molding is a quite famous technology in variety of industrial sectors. The reason of its popularity is the quick prototyping. It can enhance speed of production to an unbelievable level.

In which way injection molding service works?

The plastic injection molding service process takes into 5 multiple steps. Moreover, during this process technicians and engineers define the specific parameters, based on the type of material used and the product to be obtained:

 1). The plastic comes, in the form of pellets or granules, into the injection molding machine

 2). Moreover, the thermoplastic polymers melt 

3). similarly, the liquid plastic injects into the mold - this step is essential for the success of the plastic injection molding process because the molten material must be evenly distributed inside the mold 

4). We let the mold cool so that the plastic material inside it solidifies 

5). Furthermore, manufacturers use extraction methods for different pieces

What kind of plastic is good for injection molding service?

Plastic injection molding requires different types of thermopolymers and plastic materials which, based on their physicochemical characteristics. We divide them into:

• amorphous or semi-crystalline (depending on the structure)
• standard polymers or technopolymers (depending on temperature resistance)

Among the plastics most commonly used for injection molding, we find:

• PC polycarbonate
• ABS styrene copolymers
• Polymethylmethacrylate
• polyetherimide PEI
• polyphenylene sulfide PPS
• Do you need plastic injection molding service? We are your perfect partner! 

THE INJECTION MOLDING OF PLASTIC MATERIALS

We have specialization in injection molding for companies working in different production sectors in Europe and around the world. Therefore, in particular, we produce:

• precision technical products
• multi-cavity moldssuitable for high production
• molds for small and niche productions

# 1 Production of molds for small, medium and large volumes

Basically, we design and manufacture our precision molds according to the customer's needs, in order to obtain pieces of great technical complexity, both for large volumes and for the production of a few dozen pieces. 

Similarly, in detail, our mold production service for injection molding plastic materials includes:

• feasibility analysis
• co-design (on request)
• mold design
• prototypes / pilot molds
• construction of molds for plastic injection
• testing and testing 

Our molds for injection plastic molding

There are three main types of molds we produce , all designed on technical drawings according to the customer's needs , the field of application, the material to be used and the production volume:

• pilot molds for small and / or niche productions (even of a few dozen pieces) in aluminum or tempered steel
• molds for medium production with 2/4 cavitieswith annual consumption of 50 / 100,000 pieces
• Moreover, multi-cavity molds for high production

The maintenance of the molds by professional plastic injection molding service

The plastic injection molding service only takes place correctly if the mold is accurate and functioning, i.e. without dents or signs of wear. Therefore, for this reason, at our company we also provide a welding and maintenance service for worn molds ranging from simple cleaning to the reconstruction of entire parts.

Always look for an Authentic and Skilled Plastic injection molding service

In addition to the production of the molds, we also offer a real plastic injection molding service. Similarly, it takes place within the company and which goes from the production of pre-series batches to the creation of the finished product. 

Generally, the technologically advanced machinery we use allows us to offer, in addition to plastic molding, also services of: 

• silk-screen printing
• pad printing
• assembly of components

WHICH INDUSTRIAL SECTORS USE INJECTION MOLDING?

Plastic is now the most used material in almost every industrial sector for the production of the most disparate objects and components, such as household products, car or airplane parts, instruments for the medical sector, etc.

After all, plastic is easily malleable - not for nothing, the name derives from the Greek plastikòs. Furthermore, it means suitable for molding - and, for this reason, it is particularly good in injection molding.

The sectors with which we work the most for the plastic injection molding service materials are:

• medical and orthodontics
• automotiveand aerospace
• Moreover, electrical, electromechanicaland electronic
• housingand gate automation
• Similarly, lighting technology
• industrial automation

THE ADVANTAGES OF INJECTION MOLDING OF PLASTIC MATERIALS

Basically, plastic injection molding service is a highly versatile technique. Furthermore, it allows meeting almost any need of companies that manufacture plastic products and components both in large volumes and in a few dozen pieces.

Here, in brief, are the advantages of injection molding of plastics:

• high productivity and speed- this technique, in fact, allows to obtain large quantities of plastic parts in a short time, guaranteeing dimensional repeatability
• Similarly, possibility of obtaining shapes in disarrayand complex geometries , impossible to obtain otherwise
• In addition, a very high degree of precision, to obtain which we also resort to the technique of micro injection molding
• Moreover, reduction of production coststhrough the automation of the entire injection molding process

Conclusion

Our plastic injection molding service deals with the entire production cycle of injection molding of plastic materials. Moreover, it is for the production of thermoplastic items and components. Similarly, we are offering, if required, also services for the design and construction of injection molds.

The company guarantees maximum customization of the products for various industrial sectors. In addition, we are producing small and medium-sized components and responding to the needs of both small batches and large series.

The right tool in the shortest possible time: Injection molding of plastic products

Plastic products have become part of our daily life. It is impossible to imagine any production without them. To make a plastic part, the technology of diy plastic injection molding products is most often common. 

This technique allows you to produce serial products, as well as create individual copies. Furthermore, using special equipment, you can create miniature parts weighing 10-20 grams, as well as heavy workpieces.

Diy plastic injection molding Positive Factors

The technological process of creating products by injection molding of plastics consists of several basic operations. First, the molten material come into a mold installed on a special machine (injection molding machine), kept in it for a certain time, then it cools.

This casting is a cyclical method that affects productivity. This method is inferior to a continuous diy plastic injection molding process. The advantages of this technology include:

• Any brand of plastic is recycled;
• Manufactured products are always of the highest quality;
• The ability to manufacture products of any, even very complex shape;
• Creation of thin-walled parts;
• No additional processing is needed;
• Fully automated process

Disadvantages of injection molding technology

The main disadvantage of this technique is good to consider:

• High cost of equipment
• Complex service
• Adjustment of the injection molding machine should be good to perform only by highly qualified adjusters.

To manufacture a new product, it is necessary to design a special mold, analyze future costs, and configure equipment according to individual parameters.

Diy plastic injection molding Production technology

To get a quality part, you must strictly follow the technological requirements:

1. The plasticizing temperature is always 10 degrees higher than the plastic flow rate. If it exceeds 20 degrees, the viscosity of the polymer decreases, and the productivity begins to increase. However, this leads to a strong release of harmful substances, accelerated aging of the plastic.
2. The temperature of the material must be higher than the temperature of the mold. Moreover, it must be well heated so that uniform filling occurs.
3. The diy plastic injection moldingcycle time depends on several parameters. Thermal conductivity of plastic does not affect the performance of a given technological process, the characteristics of the heating cylinder. Similarly, the duration of the process depends on the dimensions of the mold, as well as the temperature of the melt.

Depending on the used closing mechanism, certain technological parameters must be observed:

• closing forces;
• generated pressure;
• Total low tide area;

Then the possibility of manufacturing the desired product on the existing equipment (injection molding machine) is must. Waste generated after casting is subject to recycling. They can be good to use to create other details.

It would seem that injection molding is simple: melt the plastic, pour it into a mold, let it cool and pull out the casting. But plastic molding is constantly improving.

The world's largest injection molding machine

The world's largest injection molding machine designed in 2013 and built by Infiltrator Systems in Winchester, USA. The most powerful injection molding machine produces products for septic tanks. Similarly, the mold installed in the Infiltrator injection molding machine weighs 190,508 kilograms and forms a 110 kilogram polypropylene half of the tank.

Do you need diy plastic injection molding molds for reliable temperature control?

1. Thermostat pump for sufficient flow rate of thermostatic fluid
2. Moreover, Temperature difference between inlet and outlet not less than 4 ̊C
3. Serviceability of the valve that limits the maximum pressure of the thermostatic fluid
4. All listed conditions

When should the mold safety mode be activated?

1. At the point of contact between the punch and the die
2. Until the moment the punch touches the die
3. Approximately 5 seconds before complete compression of the mold
4. From the very beginning of the punch movement

Unrecyclable waste

1. Products with mechanical damage, chips, cracks
2. Incompletely molded products
3. Furthermore, Products showing signs of overheating (thermal decomposition) over the entire surface
4. Large or hollow sprues

The problem of the residual diy plastic injection molding melts bed?

1. Ensure pressure transfer to the end of the material make-up
2. Prevent backflow of the melt, flowing out of the mold
3. In addition, Eliminate auger bouncing during injection
4. Prevent the flow of melt from the nozzle after retraction of the injection unit

The task of the reactive pressure (backwater) of the material

1. Displace the air drawn in together with the granulate towards the inlet
2. Improve the mixing quality of the melt
3. Moreover, dispense a constant amount of material
4. All listed conditions

During the diy plastic injection molding casting process, an underfilling defect appeared on the manufactured product. Indicate how you will start to fix the problem?

1. Add a dose of material. If the defect does not eliminate within two cycles, then add the injection speed
2. Wait for 5 more cycles to complete. If the diy plastic injection moldingcasting process does not stabilize, then start adjusting the parameters
3. Furthermore, pour raw materials out of the hopper to check that there is no caked lump in the feed zone, or that the secondary material is hanging. If there are no obstacles to loading raw materials, then we increase the temperature of the material cylinder
4. Evaluate the change in injection time according to the readings of the monitor. If the injection time has increased, then immediately check the heating of the nozzle, the cleanliness of its bore

In the process of casting, the mold ceased to go out to the pressure. Your actions?

1. Add the force of locking the mold and inspect the resulting product
2. Similarly, Change the on / off positions of the mold protection mode, guided by the actual location of the punch
3. Inspect the mold for the presence of a foreign object or breakage in it, and then decide to adjust the protection mode
4. Moreover, Stop the injection molding machine, call the manager.

Auger revolutionized injection molding

The original diy plastic injection molding process remained unchanged until the end of World War II. But after the devastation, there was a massive demand for inexpensive plastic products.

Rotating, the auger heats the plastic. The pellets pushed forward and pressed against the barrel. These shifts create friction and heat the plastic 60-90% of the heat required to melt. The rest of the heat comes by the cylinder tape heaters.

Plastic Injection Molds: The Challenges

We are well aware of the problems faced by those involved in the production of molds for plastic. The processes required to arrive at the final solution can dramatically affect times and costs. For this problem you need a reliable plastic injection molding manufacturing.

Complexity

Generally, an injection mold consists of many complex cavities, inserts and cooling channels.

Relevant Costs and Times

Making an injection mold with traditional methods involves high tooling costs and long delivery times.

High wear

Mold tools must be able to withstand repeated impacts and exposure to high temperature polymers.

Similarly, improving the overall efficiency of the process is essential to preserve margins and meet the deadlines set by customers and in this, professional plastic injection molding manufacturing represents a reliable ally.

The advantages of additive manufacturing in plastic injection molding manufacturing

3D printed molds and inserts are much cheaper, easier and faster to make. Moreover, using a 3D printer in making injection molds makes the whole process more efficient.

Geometric freedom, reduced machining

Additive technology in plastic or metal allows obtaining complex geometries and cavities in a simpler way, avoiding complex manual processing.

Lower construction cost

The cost of making a mold is often influenced by the need to make changes to achieve the desired final result.  Similarly, the 3D printing makes the most economic process.

Resistant materials

Metal and polymers resistant to high temperatures and mechanical stress to make additive molds that resist wear in short cycles. In addition, start your journey to improve efficiency through 3D printing today.

• Inserts for molds with shaped metal channels
• Create more efficient technical inserts with metal 3D printing

Reduce the material used and build lightweight inserts while maintaining wear resistance with a Desktop Metal 3D printer. Furthermore, it improves part quality and reduces cycle time, lowering costs and increasing productivity.

Plastic injection molding manufacturing:  The advanced alternative to reduce time and costs!

Basically, PolyJet ™ technology is a 3D printing method that allows companies to build in-house injection molds, quickly and easily. Moreover, it uses liquid photopolymers that gets the shape of desired geometry. 

We can position prototypes using plastic injection molding manufacturing efficient way. Furthermore, it is good to create prototypes of the same material required for the finished product.
These precision prototypes provide realistic examples of finished products and can be used to collect actual performance data in real-world applications.

Shape you future plastic injection molding manufacturing Project

When you have a project in mind, be it large or small, creating a prototype is definitely an important step to take. Doing a test before going into production, in fact, minimizes the possibility of evaluation and calculation errors which, if not discovered in time, would lead to waste and costly rework.

In particular, the so-called rapid prototyping with 3D printing comes to the rescue in plastic molding projects. It is a set of industrial techniques useful for creating a prototype, in a relatively short time, starting from a three-dimensional mathematical definition of the object (CAD).

Why it is useful for companies to create prototypes?

Having a prototype of the object you want to produce allows you to carry out various preventive tests , so as to verify its ergonomics, functionality, assembly, aesthetics.

3D prototypes in plastic molding projects therefore have several advantages:

• facilitateshape, size and assembly tests
• they help in the development and correct definition of the product.

A realistic prototype also represents a very effective tool for marketing actions and can be useful to all the different company areas to have a more concrete vision of the project: from Research and Development, to the Technical Office, to Marketing, to Production.

In whole process you need professional plastic injection molding manufacturing.

The plastic injection molding manufacturing techniques

The techniques for creating prototypes are numerous using plastic injections molding manufacturing. The ones we usually use are those illustrated below: according to the different needs of our customers, we direct each project towards the most suitable technique.

Multi Jet Fusion (MJF)

The technology called Multi Jet Fusion (acronym MJF) employs a printhead of the ink jet nozzles to selectively apply melting agents and detail on a nylon powder bed. The fusing agents give heat to the material by melting the particles to allow the creation of a solid layer. 

After each layer is created, the powder is redistributed on the bed and the process repeats until the piece is complete.

This process allows for a good surface finish, small details, reliable mechanical properties and short lead times.

Polyjet

Polyjet is a technology quite similar to MJF: also in this case molding heads are used and for this the final result is quite similar.

The main difference is in the removal of excess materials and support structures to arrive at the final geometry.

Plastic injection molding manufacturing technique gives precise and detailed results, but is not suitable for large quantities of parts.

SLS sintering

Using a laser radiation as in stereolithography, in the case of sintering the construction material, that is the nylon powder, is aggregated by a heat adduction that melts the particles stably, solidifying them.

This technology allows building parts with very complex geometries and with small details. The material is mechanically and heat resistant and can be further processed (eg painting and assembly of threaded inserts).

The Advantages of Additive Manufacturing in Plastic Injection Molding Manufacturing

Fused Deposition Modeling (FDM)

The construction process in Fused Deposition Modeling is based on the deposition of material by an extrusion head which, layer by layer, creates the object. Various materials can be used according to requirements.

The plastic injection molding manufacturing technology allows to create both aesthetic and functional prototypes, as well as to realize small productions thanks to the excellent properties of the materials that can be used.

For each project, a specific solution

Listening to the needs of our customers, we know how to best address each project, so as to create prototypes that reflect the physical-mechanical characteristics of the piece as much as possible , before moving on to mass production.

Plastic Injection Molds: The Challenges

We are well aware of the problems faced by those involved in the production of molds for plastic. The processes required to arrive at the final solution can dramatically affect times and costs. For this problem you need a reliable plastic injection molding manufacturing.

Complexity

Generally, an injection mold consists of many complex cavities, inserts and cooling channels.

Relevant Costs and Times

Making an injection mold with traditional methods involves high tooling costs and long delivery times.

High wear

Mold tools must be able to withstand repeated impacts and exposure to high temperature polymers.

Similarly, improving the overall efficiency of the process is essential to preserve margins and meet the deadlines set by customers and in this, professional plastic injection molding manufacturing represents a reliable ally.

The advantages of additive manufacturing in plastic injection molding manufacturing

3D printed molds and inserts are much cheaper, easier and faster to make. Moreover, using a 3D printer in making injection molds makes the whole process more efficient.

Geometric freedom, reduced machining

Additive technology in plastic or metal allows obtaining complex geometries and cavities in a simpler way, avoiding complex manual processing.

Lower construction cost

The cost of making a mold is often influenced by the need to make changes to achieve the desired final result.  Similarly, the 3D printing makes the most economic process.

Resistant materials

Metal and polymers resistant to high temperatures and mechanical stress to make additive molds that resist wear in short cycles. In addition, start your journey to improve efficiency through 3D printing today.

• Inserts for molds with shaped metal channels
• Create more efficient technical inserts with metal 3D printing

Reduce the material used and build lightweight inserts while maintaining wear resistance with a Desktop Metal 3D printer. Furthermore, it improves part quality and reduces cycle time, lowering costs and increasing productivity.

Plastic injection molding manufacturing:  The advanced alternative to reduce time and costs!

Basically, PolyJet ™ technology is a 3D printing method that allows companies to build in-house injection molds, quickly and easily. Moreover, it uses liquid photopolymers that gets the shape of desired geometry. 

We can position prototypes using plastic injection molding manufacturing efficient way. Furthermore, it is good to create prototypes of the same material required for the finished product.
These precision prototypes provide realistic examples of finished products and can be used to collect actual performance data in real-world applications.

Shape you future plastic injection molding manufacturing Project

When you have a project in mind, be it large or small, creating a prototype is definitely an important step to take. Doing a test before going into production, in fact, minimizes the possibility of evaluation and calculation errors which, if not discovered in time, would lead to waste and costly rework.

In particular, the so-called rapid prototyping with 3D printing comes to the rescue in plastic molding projects. It is a set of industrial techniques useful for creating a prototype, in a relatively short time, starting from a three-dimensional mathematical definition of the object (CAD).

Why it is useful for companies to create prototypes?

Having a prototype of the object you want to produce allows you to carry out various preventive tests , so as to verify its ergonomics, functionality, assembly, aesthetics.

3D prototypes in plastic molding projects therefore have several advantages:

• facilitateshape, size and assembly tests
• they help in the development and correct definition of the product.

A realistic prototype also represents a very effective tool for marketing actions and can be useful to all the different company areas to have a more concrete vision of the project: from Research and Development, to the Technical Office, to Marketing, to Production.

In whole process you need professional plastic injection molding manufacturing.

The plastic injection molding manufacturing techniques

The techniques for creating prototypes are numerous using plastic injections molding manufacturing. The ones we usually use are those illustrated below: according to the different needs of our customers, we direct each project towards the most suitable technique.

Multi Jet Fusion (MJF)

The technology called Multi Jet Fusion (acronym MJF) employs a printhead of the ink jet nozzles to selectively apply melting agents and detail on a nylon powder bed. The fusing agents give heat to the material by melting the particles to allow the creation of a solid layer. 

After each layer is created, the powder is redistributed on the bed and the process repeats until the piece is complete.

This process allows for a good surface finish, small details, reliable mechanical properties and short lead times.

Polyjet

Polyjet is a technology quite similar to MJF: also in this case molding heads are used and for this the final result is quite similar.

The main difference is in the removal of excess materials and support structures to arrive at the final geometry.

Plastic injection molding manufacturing technique gives precise and detailed results, but is not suitable for large quantities of parts.

SLS sintering

Using a laser radiation as in stereolithography, in the case of sintering the construction material, that is the nylon powder, is aggregated by a heat adduction that melts the particles stably, solidifying them.

This technology allows building parts with very complex geometries and with small details. The material is mechanically and heat resistant and can be further processed (eg painting and assembly of threaded inserts).

Fused Deposition Modeling (FDM)

The construction process in Fused Deposition Modeling is based on the deposition of material by an extrusion head which, layer by layer, creates the object. Various materials can be used according to requirements.

The plastic injection molding manufacturing technology allows to create both aesthetic and functional prototypes, as well as to realize small productions thanks to the excellent properties of the materials that can be used.

For each project, a specific solution

Listening to the needs of our customers, we know how to best address each project, so as to create prototypes that reflect the physical-mechanical characteristics of the piece as much as possible , before moving on to mass production.

Your Comprehensive Guide on Plastic Corner Molding in China

Sharp edges no doubt look great. But, they can be huge trouble when molding plastic parts. They increase stress concentration which can lead to part failure. These sharp edges most commonly occur in non-obvious places such as a strengthening rib. For this reason, plastic corner molding in China tries to avoid it at all costs. Want to learn more about the design considerations for injection molding? This guide will tell you everything that you need to know. Keep reading!

Design Considerations for Plastic Corner Molding in China

There is a huge risk of error while designing corners for plastic corner molding in China. These issues can range from small surface faults to some grave problems that can impact the performance and the functionality of the product. These errors can occur due to many problems such as the process of the molding, the material used, and the tooling design.

We have listed some obvious mistakes that make occur while molding the edges of a plastic product below. Let’s take a look at them.

1.      Flow Lines

Flow lines look like a curvy pattern and are of a different color than the rest of the area. These lines occur due to difference in the cooling speed of the material when it flows in multiple directions in the mold. They most commonly appear on the narrower sections of the molded component.

Sometimes, they are even visible as ring-shaped bands on the surface of the product near the entry points. Although these lines do not impact the integrity of the product, they can be unpleasing to the eyes. Moreover, the consumer may even reject the product if they found flow lines on it.

2.      Warping

Warping is another common defect that occurs during plastic corner molding in China. It is a sort of deformation that appears when different parts of molded products are shrunk unevenly. When the shrinkage is uneven, it puts stress on different parts of the product. As a result, bending of the finished part takes place.

It occurs when the cooling process takes place too quickly. Furthermore, the excessive temperature can sometimes make the problem worse. Another reason for warping can be the mold design. When the walls of the design are of uneven thickness, this may also result in warping.

3.      Burn Marks

These marks look like rust-colored or black discoloration and may appear on the corner or the surface of the molded plastic part. Generally, these marks do not affect the integrity of the product unless the product burns so much that it is degraded.

So, why do these marks occur on plastic products? Well, the most common reason that they appear is because of the trapped air, overheating, and resin during the mold cavity. So, if you want to avoid these burn marks, you must lower the melting temperature and reduce the injection speed.

4.      Sink Marks

For those of you who don’t know, sink marks are depressions that appear on the surface of the product that is extremely flat and smooth. These marks appear in the plastic product when its inner molded part shrinks.

When the inner part shrinks, it pulls the material from the edges inward. So, what causes the depression in the surface that was smooth and flat before? The sink marks appear when the molded material takes a lot of time to cool down.

This results in shrinkage which then pulls the material from the edges inwards before it has the chance of cooling down. As a result, depressions in the form of sink marks occur.

5.      Air Pockets

Air pockets are air bubbles that are trapped in a finished product that is molded. Although it is considered a small defect by the quality control professionals, the large and numerous voids have the power of weakening the plastic product.

That’s because the air is below the surface of the product where the molded material should have been. Unsuitable molding pressure is one of the most common causes of air pockets or vacuum voids. The inadequate molding pressure forces the air that is trapped in the product from the mold cavity. As a result, air pockets may occur in the edges of the plastic molded product.

6.      Jetting

Jetting is a kind of a corner molding defect that appears when a jet of molten material is injected into the mold cavity. The major cause of jetting is all the extra injection pressure.

When the material solidifies before the cavity is filled, it results in jetting. It does not only look unpleasing to the eyes but it can result in the weakness of the product as well. Therefore, it should be avoided at all costs. You can reduce the injection pressure and increase the mold and material temperature to avoid jetting.

7.      Weld Lines

Weld lines are another common molding mistake that appears in the products of plastic corner molding in China. These lines appear on the surface of the edges where the molten material has converged after splitting into different directions in the mold.

This results in hair-like weld lines. These lines have the capability of weakening the strength of the product. Therefore, they must not be taken lightly and should be avoided at all costs.

So, how can you avoid weld lines in your plastic molded products? Well, the answer is extremely simple. All you need to do is increase the temperature of the material during molding and raise the speed and the pressure of the injection.

Final Words

Although sharp edges look pleasing to the eyes, they are not suitable for plastic corner molding. They can result in the weakening of the product. For this reason, they must be avoided at all costs.

We hope the above mentioned defects will help you identifying the molding defects when you see one so that you can avoid them later. For more information, reach out to us and we will be happy to assist you.

What Plastic Injection Molding Service in 2021 Will Look Like?

Injection molding service is extremely effective and simple. Not only this, but this manufacturing process has a rich history as well. According to historical pieces of evidence, the first injection molding machine was created in the year 1872. The manufacturers used a plunger to inject plastic into a mold. The plastic injection molding service has been slowly progressing ever since the invention of the first injection molding machine. Various trends are introduced each year. Want to know what trends the plastic injection molding service in 2021 will introduce? Keep reading then.

The History of Plastic Injection Molding Service

Although the molding industry has been slowly developing ever since the initial development of the first injection molding machine, it went through a renaissance in the year 1940. That’s because World War ll increased the demand for mass-produced products. That is why James Watson Hendry built the first extrusion screw injection machine as well. He built the machine in the year 1946 to provide greater control to the engineers. As a result, they were able to make countless contributions to the injection molding industry today.

What Trends The Plastic Injection Molding Service in 2021 Will Introduce?

You will notice the use of plastic injection molding services in a variety of industries these days. It is not only used in the aerospace industry but for manufacturing children’s toys and for packaging as well. Even though the technology has been around for many years, every year brings new technological advancements to the service. But, the important thing to note here is that these advancements depend on many factors such as market disruptions and some other social-economic factors.

Want to know how the plastic injection molding service in 2021 will revolutionize? Keep reading then.

1.      The Demand in Medical Industry Will Increase

It is common knowledge that the medical industry is replacing metal components and other equipment with plastic injection molded products. Some common examples that represent the shift include catheters, syringes, instruments, braces, implants, diagnostic equipment, and a lot more. The reason behind the shift is that plastic products are not only more compliant but the global marketplace of these products is also huge. In addition to this, there are a lot of design options and minimal side effects of manufacturing that plastic molded products offer to the users. Moreover, plastic products are more biocompatible and the recycling options are unlimited as well. All of these factors are the reason that the demand for plastic molded products in the medical industry will rapidly increase in the year 2021.

2.      Increase in Demand in Contract Manufacturing

Contract manufacturing is an extremely popular option for a lot of manufacturers out there. This option is not only time-saving but incredibly cost-effective as well. Moreover, the product will also have a specialized partner that will do a portion of the work to launch a new product in the market. For this reason, the manufacturers choose to have a contract partner that will do all the work related to injection molding services. Since it is the preferred method of a lot of people, its demand will increase in the current year as well. More and more service providers will shift to the small-scale contract manufacturers that will take care of the manufacturing process for them.

3.      More Reshoring

The global pandemic that started in the year 2020 reflected the weakness in logistics all over the world. Not only this, but it also showed how many industries took advantage of trade options that were available to them outside the US. Since a lot of low-cost options for offshore companies were stopped due to the outbreak of COVID-19, the need for reshoring rose.

More and more companies are reshoring their manufacturing and tooling. That’s because the companies are realizing that their tooling will no longer be brought back to the US. This is why the year 2021 is reflecting a huge shift in recovery services. These services are playing a huge role in helping the companies retrieve, inspect, and get back their tools as soon as possible.

4.      More Focus on Sustainability

Sustainability is an extremely important subject that will continue to grow in the year 2021. That’s because it has a huge impact on the climate as well. The goal this year is to decrease wastage and cut emissions.

In addition to this, recycling will continue to trend in the year 2021 as it has been for the past few years. The recycling goal this year is to reach 100% recyclability. Since so much focus is placed on recycling, it will not be wrong to say that recycling has become a separate industry of its own. Moreover, some experts and consultants even tell you different recycling options that you have.

5.      A Renewed Interest in Bioplastic

Since sustainability is trending this year, many manufacturers are going to explore the advantages of using bioplastic in injection molding and mold-making. Also known as PLA bioplastic, bioplastic is a great alternative to petroleum-based plastic.

For those of you who do not know, petroleum-based plastic is derived from seaweed, corn, sugarcane, or shrimp shells. On the other hand, bioplastics are biodegradable and can break down to biomass and natural environments. So, if the packaging is done using bioplastic, the manufacturers will contribute to an eco-friendly market and reduce environmental hazards as well.

6.      Experimenting With Material Alternatives

One of the major trends in the year 2020 was the use of composite materials. This revolutionized the entire automotive and aerospace industry. That is why we expect this trend to continue in the year 2021 as well.

What’s more, there are huge advantages associated with using composite material as well. They are not durable and flexible, but cost-effective as well. So, their trending is highly justified.

Final Words

The year 2020 was no doubt unpredictable. The same is expected from 2021 as well. But, no matter how unpredictable this year is going to be, some things are never going to change and the plastic injection molding trends mentioned above are a great example of it.

For More information, Contact Us Today!

How to Deal With the Designs of Plastic Injection Molding Factory

Injection molding is a manufacturing process that is used by the plastic injection molding factory. The manufacturers use this process for the mass-production of plastic parts that are completely identical. Not only this, but the plastic parts that are produced are of good tolerance as well. The process involves melting polymer granules and then injecting the liquid into a mold.

The plastic injection molding factory manufactures a lot of products such as car parts, kitchen appliances, and electronic enclosures. But, several factors might affect the quality of the final design of the product. Want to know more about it? Keep reading then.

What is the Process of Plastic Injection Molding?

Plastic injection molding is the process of engineering plastic molds. That’s because plastic has resilient qualities. It allows the easy absorption of heat. Plastic injection molding is not only used in engineering applications but consumer products as well.

It is capable of producing identical plastic products that have high volumes. Moreover, the cost incurred by the plastic injection molding factory is extremely low as well. The molding machines are extremely easy to maintain and produce identical batches that quite impossible to differentiate.

How Do Injection Molding Machines Work?

Primarily, the injection molding machine is constructed with three main parts. These parts are known as the injection unit, the mold, and the clamping unit. The clamping unit is the most important part of the entire plastic injection molding process.

The main purpose of the injection unit in an injection molding machine is to melt the raw plastic and direct it into the mold. To carry out its assigned work, it consists of the reciprocating screw, hopper, and barrel.

The next step is to manufacture the mold. The mold is just like the negative part of the photograph. The texture of the mold is transferred to the injection molded part of the molding machine.

You will notice the clamping and the ejection system at the farthest side of the injection molding. The clamping system of the machine serves two main purposes. It not only keeps the parts of the mold shut tightly but also plays an important role in pushing the part out of the mold once the molding is complete.

What are the Applications of Plastic Injection Molding?

The resistance to heat and other chemicals makes plastic injection molding extremely popular. Due to its popularity, plastic injection molding is used in a lot of industries. Some common applications are mentioned below.

• Electronic Appliances
• Home Appliances
• Automotive Parts
• Construction Appliances
• Engineering Equipment

What is the Reason behind the Popularity of Plastic Injection Molding?

Plastic injection molding is a common manufacturing process among plastic injection molding factories. That’s because of the benefits that this manufacturing process offers. Let’s take a look at some of its amazing advantages below.

• Recyclable
• Easier to glue
• High tensile strength
• Low cost
• Strong impact resistance
• Suitable for extreme temperature
• Scratch resistance
• Shock absorbance
• Easier to color
• Heat resistance

Some Common Designing Defects Incurred By a Plastic Injection Molding Injection Factory

Sometimes, a defect may occur in the design of the final product of the plastic molding. The plastic injection molding factory incurs these defects due to several reasons. Let’s check out some common designing defects below.

1.     Warping

When a certain part of the plastic product cools down faster than the other parts, it starts shrinking. The shrinking of that specific part can result in permanent bending of the object. That’s due to the internal stress that the product faces. This is what warping is called. The parts of the plastic product that have thick walls than other parts are more prone to warping.

2.     Sink Marks

When the inside of any part of the plastic product solidifies quicker than its surface, a small sink mark may appear in that specific part. This is why it is known as a sink mark. The parts of the plastic product that have a higher risk of sinking are the parts that have poorly designed ribs or have thick walls.

3.     Drag Marks

Another common defect in the design of a plastic product manufactured by a plastic injection molding factory is known as drag marks. It occurs due to the shrinking of the plastic. That’s because when the plastic sinks, it applies pressure on the mold.

As a result, the walls of those specific parts will slide during the ejection process. Not only this, but the walls will also scrape against the mold. This may result in drag marks. The parts that are more prone to drag marks are the parts that have vertical walls.

4.     Knit Lines

When two flows of a plastic product meet, you may notice it developing hair-like discolorations. These hair-like discolorations are extremely small. That’s called knit lines. The parts of the product that are more prone to knit lines are the ones that have holes in them. Knit lines not only ruin the aesthetics of the product, but it makes the plastic product weaker as well.

5.     Short Shots

Short shots may occur in plastic products that have extremely thin walls. Sometimes, the air that is trapped in the mold can block the flow of the plastic during the injection molding process. This might result in the product coming out as incomplete. For this reason, it is extremely important to design products that have a flawless design. When the design is good, it will improve the flow of the melted plastic.

Final Words

Plastic injection molding is extremely popular among the manufacturing industries these days. That’s due to the many benefits offered by this process. For this reason, many plastic injection molding factories are using it as well.

But, some common design defects may incur if you do not observe the process closely. This is why you must observe the entire process extremely carefully. For more information, contact us now!