Accuracy, speed, lowered costs and durability are the foundations of success for businesses across industries.
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These are the attributes your customers seek from your product. When your business is looking to bring a high-quality product into the market and achieve a competitive edge, the precision of your products’ components is paramount.
Plastic injection moulding is an optimal solution that offers precision, accuracy, durability and cost savings for your business with the ability to fabricate any plastic component of varying complexity.
The multiple benefits offered by the process is the reason why a growing number of businesses are using injection moulding for manufacturing components and products. According to recent research, by , the global injection moulding market revenue is slated to reach $500 billion. There is a growing demand for injection moulding in regions across the world, including South Africa, with a 4 per cent annual increase in demand.
There are many reasons why injection moulding is emerging as one of the most popular technologies.
https://pimmsmanufacturing.co.za/materials-plastic-injection-moulding'>Plastic pellets are introduced into the injection moulding machine with the help of a hopper. These pellets gravitate towards the mould near the injection unit. The heat and pressure that is applied the barrel ultimately melt the pellets.
A hopper feeds plastic pellets into the moulding machine. The plastic pellets melt due to the pressure and the heat around the barrel, and the melted plastic is then injected within the mould.
As the melted plastic enters, it displaces air, which escapes through the vents located along the splitline of the part and/or ejection pins across the part face. The design of the gate, runner and vents are crucial to ensure that the mould gets properly filled.
When the mould is filled between 95 to 99 per cent, the injection timing is complete. Injection time is also estimated with other factors, including shot volume (the volume of material) power and injection pressure.
The process continues with the separation of usable parts from the runner, which is the pathway the plastic uses to fill up the mould cavity.
The runners may be ground and recycled in order to minimize environmental impact and to reduce costs. In higher volume products, the use of a hot-runner system can be implemented to eliminate the need for recycling cold runners.
The usable parts taken from the runner are counted, quality checked, weighed and packaged for shipping or for assembly.
A sophisticated injection moulding manufacturer has a highly experienced team of designers and engineers apart from established quality control processes. This ensures that both the design and manufacturing processes are optimized and streamlined to enhance efficiency.
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After the designing of injection moulds as per customer specifications and pre-programming of the machine, the process of moulding is very quick in comparison to other plastic moulding processes.
Injection moulding is also fast. Although the speed generally depends on the mould’s complexity and part size, the time taken for each cycle of production is between fifteen to Sixty seconds Depending on the tool design – Multi cavity tools can allow for parts to be produced in a fraction of a second.
Whether this is your first product or your fortieth, if you’re not currently using plastic injection molding, you’re missing out on some great manufacturing options. Regardless of if your concerns are part accuracy, using plastics instead of metals, or if it’s really the most cost-effective option for your needs, we think this top ten list will help convince you to revisit using plastic injection molding for your product.
Once the mold for a plastic part is created, the volume of production can be scaled up or down at need, from a few thousand a month to over a million. Multi-part molds and different plastic resins can extend that number even further. Learn more about low and high-volume production.
Plastic injection molded parts can have as high an accuracy and quality as needed. Especially using state-side manufacturers, accuracy will be well within 0.001 inches and through quality control measure like ISO Certification guarantees your parts are all of the highest accuracy and quality.
After the initial cost of the injection mold, the cost per part is very, very low. While your resin selection will contribute to the range of cost, with a low overhead in terms of manpower and machine wear, costs per part are lower than any other manufacturing option at high production volumes.
Did you know that plastic parts can be as strong as steel? This comes from two major factors: modern plastics that can be super-strong and the ability to design plastic structures to maximize engineered strength in ways metals can only dream of.
Speaking of engineering designs, plastic injection offers options you can’t find in other mediums. With the right plastics and designs, your plastic can take on even more complex features, such as the living hinge that provides more flexibility and lowered costs.
Plastics and their inject molds allow for greater design freedoms than many other manufacturing features. Under the hands of an expert mold maker, you can produce parts and sets of parts that require less work after manufacturing, from smoother finishes to intricate designs.
Does your business and its customers value greener and leaning manufacturing? Many plastics used in injection molding are thermoplastics: recyclable and reusable both in manufacturing and for end-users. There is also the ability to use biopolymers – plastics made from renewable biomass such as woody fibers and starches.
Parts don’t have to be made of a single plastic. Overmolding and double-shot molding allows two plastics with different qualities (such as flexible and hard) to be joined together in the mold. Co-injection molding allows one polymer to be injected as the core of another, allowing for more flexible and cheaper parts.
The wide-spread use of injection molding means you have more flexibility where your molds and parts are produced. Overseas molding has its benefits and drawbacks, depending on your needs. However, if you ever need to you can always relocate your tool to another manufacturer.
Plastic injection molding has been around for a long time, and has the tools and standards to meet multiple markets. For example, if you’re making medical parts and need traceability, there are options to make sure every part can be traced back to its batch.
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