Introduction:

Plastics injection molding, also known as injection molding, is a molding method that combines injection and molding. Although there are many advantages and disadvantages of injection molding, the advantages of injection molding are the main aspects,The advantages of the advantages of injection method are fast production speed and high efficiency, the operation can be automated.

At a some temperature, a completely molten plastic material is stirred by a screw, injected into the mold cavity with high pressure, This method is suitable for mass production of components with complex shapes and is one of the important processing methods. Below, the benefits of injection molding are explained in detail.

High Efficiency of Injection Molding And Realization of Economies of Scale

Why is Injection Molding More Efficient?

High degree of automation:

Traditional mold production is not only complex but also takes a relatively long time. For today’s fast-paced industrial production model, this mold production method can no longer adapt to the requirements of the times. The entire injection mold manufacturing process can be automated, which effectively improves the production efficiency of mold products, and all processes can be completed at one time.

High-speed production:

The injection molding process is faster and more efficient than other molding processes, which can greatly improve production efficiency. In addition, the injection molding process can also realize automated production, reducing labor costs and human errors.

Compared with traditional injection molding, high-speed injection molding reduces the man-machine ratio and labor intensity. It uses mechanical automation to replace most of human actions, embodying “quantity” To win; this process requires high mechanical automation and assembly line operations.

Precision injection molding is developed on the basis of high-speed injection molding and is specialized in producing products with higher added value. It embodies the credibility obtained by “quality” and the profit obtained by “quantity”.

The finished product has high precision:

There are two definition indicators for precision injection products, one is the repeatability of product size, the other is the repeatability of product quality. The most important technical indicator for evaluating products is the accuracy of injection molded products.

Precision injection molding machines require product dimensional accuracy generally within 0.01~0.001mm. the mold clamping system is required to have sufficient rigidity and high enough mold clamping accuracy.

How Does Injection Molding Achieve Economies of Scale?

The rapid development of the downstream field of plastic injection mold has driven the continuous expansion of the injection molding product market. Compared with metal, stone, and wood, plastic parts products have the advantages of low cost and strong plasticity. They are widely used in the national economy.

Plastic injection molding process occupies an extremely important role in the world today. status, the production ofplastic injection moldproducts has developed at a high speed around the world for many years.

Plastic injection moulding machines have a wide variety of plastic molding products and a wide range of applications. Especially in the textile equipment and automobile manufacturing industries, there are various shapes of injection molded products used as accessories.

As a result, mass production can be carried out, production efficiency can be improved, and the cost per unit product can be reduced, thereby achieving economies of scale.

High precision of Injection Molded parts And Durability of Finished Products

How Does Injection Molding Achieve High Precision of Parts?

Precision injection molding is a technical process that requires the use of precision molds and precision machines. Modern injection molding machines can produce high-precision parts with tight tolerances, ensuring that every part is nearly identical.

Precision molding technology is adopted, multi-stage injection molding is adopted, and the mold temperature is precisely controlled. Use a precision injection molding machine to replace a conventional injection molding machine.

For the shrinkage characteristics of the molding material, use plastic with high dimensional stability. For the material of the precision mold, choose alloy steel with high mechanical strength. The materials used to make the cavity and sprue must undergo strict heat treatment. It is a material with high hardness (molded parts should reach about HRC52), good wear resistance and strong corrosion resistance.

Why are Injection Molded Finished Products Durable?

Injection molding can add fillers to the injection mold, such as polyethylene (PE). PE is divided into three categories with different densities: high-density polyethylene (HDPE), low-density polyethylene (LDPE) and polyethylene terephthalate Ester (PET).

Typically, PE grades are ductile, have good impact strength and creep resistance (can withstand mechanical loads for long periods of time without deforming). Additionally, they are resistant to chemical reactions.

HDPE is stronger and stiffer. Therefore, it can be used to mold items such as kettles, bathtubs, and pipes, Thermoplastic Polyurethane (TPU) TPU is another rubbery plastic blend whose polyurethane component has highly desirable qualities.

It is very hard and has good compressive strength, abrasion resistance and chemical resistance. Furthermore, these properties do not change much under extreme temperatures.Nylon Polyamide (PA) Nylon is an excellent material with high toughness, heat resistance and surface friction/wear properties.

Polypropylene (PP): From chemical and electrical resistance to high elasticity. It also has a high melting point and PP has high stress resistance and high tensile strength. It is a strong plastic commonly used for insulation, but most manufacturers add fillers to this resin to increase strength. polycarbonate(PC): Polycarbonate has high impact resistance. Polycarbonate has high fire and heat resistance,

Injection Molding Material Color Flexibility And Complex Part Design

How Flexible is the Material And Color of Injection Molding?

Commonly used injection molding materials include acrylic (PMMA), acrylonitrile butadiene styrene (ABS)Nylon polyamide (PA), polycarbonate (PC), polyethylene (PE), polyoxymethylene (POM), polypropylene (PP), polystyrene (PS), thermoplastic elastomer (TPE), thermoplastic polyurethane (TPU) ).

Injection molding is available in a wide range of colors, including natural tones, from black to dark brown, composite colors, color masterbatch, solvent coloring, and dry pigment mixing. Through injection molding, manufacturers can use a variety of materials to form a variety of colors , thereby enhancing the aesthetics and functionality of the product.

Why Can Injection Molding Enable Complex Part Design?

Rich types of molds:

If the products designed by enterprises want to be mass-produced, they must be inseparable from the manufacturing of product molds. Traditional mold manufacturing usually has many insurmountable obstacles, And the production process is long,resulting in the inability to produce suitable mold products for high output production.

Injection mold manufacturing uses injection molding, which effectively expands the production range of mold products. This is one of the main reasons why injection mold manufacturing can design complex parts.

No limit on mold size:

Due to the limitations of mold opening technology, traditional molds have strict restrictions on the size of products. Products that are too large or too small cannot be completed through mold manufacturing. Injection mold manufacturing has no restrictions on the size of the mold, so injection molding can carry out complex part design.

Injection Molding Automation Potential And Unit Cost reduction

Why Does Injection Molding Have Automation Potential?

The entire process of injection molding is automated and computerized in all aspects through automated processing systems. Advanced processes allow for fluidic and customizable manufacturing cells.

The process of precision mold and design engineering is carried out through cells that can be computer programmed for injection molding, coating, testing and even packaging. The mechanical features of the process are highly customizable, where mechanical mounts such as lens mounts, snaps, and various other fixtures can be easily installed or removed as needed,Injection molding therefore has automation .

How Does Injection Molding Reduce Unit Costs?

Purchase wide specification resin

Resins with large performance variations are cheaper, but for products with tight tolerances, it is difficult to ensure or maintain product dimensions. This undoubtedly increases variability, which leads to higher scrap rates. But with DECOUPLED MOLDING® technology and cavity sensors, it could be a successful venture.

Shorten cycle time

Utilize scientific molding technology and DECOUPLED MOLDING® (section molding) technology to optimize clamping force/ejector action, filling time, feeding time, holding time and cooling. Use a smaller pad to form a good product and shorten cycle times.

Increase efficiency through automation

With molding technology and training, multiple areas of production can be automated, helping to increase labor efficiency. Product grabbing, product stacking and palletizing are three useful automation methods,waste plastic typically can be reduced,Thereby reducing the unused or waste plastic. Then improve efficiency through automation

Reduce risks and quality costs

Use scientific molding principles to develop repeatable and stable processes. Once a process has been developed using sensors and molding technology, various common injection molding defects in injection molding can be monitored to ensure 100% quality assurance for customers.Ultimately reducing risks and quality costs.

Conclusion

In summary, injection molds give raw materials a complete structure and precise-sized processing tools, which are suitable for product manufacturing in various industries. They can produce products in batches with high efficiency on a large scale, thereby achieving economies of scale.

The automation potential of injection mold molding processes It can realize batch manufacturing of products with consistent appearance, shape and product structure, and reduce unit costs; it has the advantages of rapid product formation and durability of finished products.

Injection molds can also manufacture products suitable for various industries based on the appearance, performance, and usage of the product. It is a modern The most respected mold industry.Injection molded products have become indispensable means of production and consumer goods.