Originally published on fastradius.com on August 26,
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Injection molding is a useful method of production that gives manufacturers the ability to create identical parts in high volumes with consistent quality and characteristics. During production, a pressurized nozzle shoots molten plastic into a durable metal mold designed to let the part cool and be ejected quickly. Once the part is ejected, the press closes and the operation repeats itself. Many everyday plastic items — from combs and bottle caps to car parts and gears — are produced through injection molding.
Historically, injection-molded parts had to be manufactured in large quantities in order to offset high startup costs. A hardened steel mold costs tens of thousands of dollars and can take weeks or months to tool, but over time, its durability allows manufacturers to recoup their investment while also lowering cost-per-part.
However, as markets evolve — evidenced, for example, by the ongoing shift toward custom and small batch products — manufacturers are adapting their operations to take advantage of new, more efficient methods. Low-volume injection molding is one of those methods.
The process of low-volume injection molding eschews hardened steel molds and inserts for softer aluminum ones, which are typically easier and cheaper to make. These molds obviously aren’t as durable as their hardened steel counterparts, but the advantage for manufacturers is that they often don’t need to be when producing parts in low volumes. When used strategically, soft molds can ultimately reduce tooling costs and shorten production schedules.
Typically, low-volume injection molding refers to making parts in quantities of 100,000 or fewer. While that number probably seems high to a layperson, it’s still relatively low compared to high-volume production numbers, which can easily reach tens of millions of parts. While 100,000 isn’t an official cutoff, it serves as a general benchmark for the point at which aluminum molds become less cost-effective than investing in hardened steel molds.
At the same time, hardened steel required for traditional molds demands a significant upfront investment of time and money. However, aluminum and lower-grade steel molds are far less expensive to create and can be produced faster. With these molds, manufacturers can prototype and produce viable parts without having to commit to high minimum orders, while continuing to refine part design and production as needed. This allows manufacturers to begin production sooner, and in many cases, accelerate speed-to-market significantly, thereby reducing the time it takes to see a return on investment.
Shorter lead times are especially beneficial for smaller product teams on tight budgets, who can now produce parts with relatively low minimum orders while still turning a profit. Furthermore, storing and disposing of excess inventory can quickly become expensive, but low-volume rapid injection molding helps to minimize excess by enabling production teams to manufacture parts only in the quantities required.
In addition to creating opportunities for creating small-batch or custom parts, the rapid injection molding process provides an efficient means of bridge tooling. This allows manufacturing companies to begin tooling hardened steel molds while simultaneously employing aluminum molds to produce parts in the meantime.
Another significant benefit of employing softer injection molds is that they rarely have a detrimental effect on part quality: plastic pieces produced in low volumes are as good as those created via hardened steel molds when proper design considerations are taken into account.
There are a few important considerations that need to be kept in mind when designing parts for manufacturability at low volumes, including general part complexity, draft, wall thickness, and surface finish.
Typically when you work with aluminum, you do not want to implement side actions or lifters normally associated with complex builds into the tool. While those operations typically cause wear in the tool — softer aluminums cannot withstand such pressure for very long — low-hardness steels like P20 serve as optimal replacement tooling materials.
Draft refers to a taper incorporated into design that makes it easier for a part to be ejected from its mold. Consider a rectangular baking pan — if the pan were truly rectangular, it would prove difficult to remove a cake. However, rounded edges and tapered sides incorporated into the design of the pan allow the cake to easily emerge. This is a principle that holds true when removing injection-molded parts from their molds, as well. All vertical faces should have at least 0.5 degrees of draft, though closer to 2 or 3 degrees is preferable if part design allows. Some complex surfaces may require as many as 5 degrees of draft.
The thickness of a component’s walls also needs to be considered, as thicker walls don’t necessarily equate to greater strength or performance — especially when working with thermoplastic materials. Thick cross-sections actually increase the likelihood of parts developing warp or sink during the cooling process, which is why wall thicknesses should typically stay between 0.040 to 0.140 inches (1 to 3.5 millimeters) across the part’s entirety.
Manufacturers can also save on tooling costs and lead time by forgoing unnecessary surface finishes to their molds. If the part’s application does not require an extremely smooth surface — which can involve hand-polishing mold cavities with diamond buffs — there’s probably no need to have it. Using the most cost-efficient finish compatible with a given part’s application is key to lowering production costs and improving production times.
Injection molding is an incredibly useful manufacturing method often leveraged to create large numbers of identical parts. The high cost of tooling the hardened metal molds means that the parts must be produced at high volumes in order for the project to prove cost-effective. However, developments in manufacturing processes and technology now enable product teams to economically create rapid injection-molded parts in smaller quantities and to provide efficient bridge tooling solutions.
Injection molding is one of the most popular and cost-effective methods for the mass production of parts. It’s used to make a wide range of items, from car parts to consumer products, but it’s also used to produce low-volume products. Low volume injection molding is a specialized process that involves creating parts with less than 100 pieces.
However, these projects are often time-sensitive and require close attention to detail, so it’s important to understand what this molding does and when you should use it. In this blog post, you’ll learn the basics of low volume injection molding and when it might be the best option for your project.
It is a process used to create plastic parts in small quantities. It is typically used for prototypes or short-run production. The process is similar to traditional injection molding, but the equipment and materials differ.
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Also, Low volume injection molding uses molds that are smaller and simpler than those used for mass production. The machines are also smaller and use less force, making them less expensive and easier to set up.
Meanwhile, the main advantage of low volume injection molding is that it allows you to produce parts quickly and cheaply. It is also well suited for producing complex shapes that would be difficult or impossible to create with other methods.
The benefits of low volume injection molding are many and varied, but the most commonly cited ones are its affordability and speed. Low volume injection molding is an excellent option for prototyping and small-scale production runs, as it is typically much less expensive than traditional injection molding methods.
Additionally, low volume injection molding can be completed in a fraction of the time of traditional methods, making it an ideal solution for time-sensitive projects.
As the name implies, low volume injection molding is best suited for applications requiring small parts. In many cases, it is the only viable option for prototyping or short-run production. Low volume injection molding has several advantages over other manufacturing methods, including:
– Reduce lead times: Because low volume injection molding uses existing molds, there is no need to wait for tooling to be created. This can significantly reduce lead times, especially for prototypes.
– Reduce costs: Low volume injection molding is typically more cost-effective than other methods, such as CNC machining or 3D printing, especially when large quantities are not required.
– Increase design flexibility: Low volume injection molding makes it possible to make changes to the part’s design without incurring significant tooling costs. This makes it an ideal option for prototyping or making small batches of parts with different designs.
The procedure of plastic injection molding can be used to produce multiple units of the same object. Small parts or products with intricate detailing are frequently done via injection molding. When injection molding is used to create objects in low volumes, it is typically referred to as low volume injection molding.
You require low volume injection molding services for a number of reasons. You may have designed a new product and need to create prototypes before going into total production. Or you could run a business that requires periodic production runs of a few hundred parts at a time.
Also, setting up and tearing down an injection mold each time would be too costly and impractical. Whatever your reasons for needing low volume injection molding, there are a few things to keep in mind when looking for a supplier.
Firstly, consider what materials you will need your parts molded from. Injection molding can be done with many different plastics, but not all suppliers will offer all materials. Make sure to find a supplier who can provide the material you need.
Secondly, take time to understand the different processes involved in injection molding and how they might affect the final cost of your parts. For example, some suppliers may charge more for molds that require multiple cavities or complex geometries.
Finally, get quotes from multiple suppliers before making your decision. Injection molding services can vary widely in price depending on the size and complexity of your project.
In conclusion, low volume injection molding is a great option for businesses looking to produce plastic parts and products in smaller quantities. Using this technique, you can save time and money on production costs while still maintaining quality. This technology has revolutionized the manufacturing industry by providing rapid prototypes that have enabled companies to launch new products much faster.
Also, there is a company called Quickparts that is your go-to partner for 3D printing and traditional manufacturing services. They excel in producing parts across a wide range of processes, so you can count on them whether you need prototypes or volume production. With their in-house production capabilities and manufacturing partners worldwide, they can manufacture your parts quickly and efficiently, wherever and whenever you need them!
Injection pressure is one of the essential variables in injection molding, and it directly affects the quality and the cost of the final product. Low injection pressure can cause several problems, including:
There are several ways to increase injection pressure. One is to use a higher-pressure pump. Another is to increase the force with which the screw is driven. The third way is to increase the back pressure on the screw.
One of the critical factors in injection molding is the holding time. This is when the molten material is held in the mold before being injected. The holding time is essential because it allows the material to cool and solidify, which helps to create a stronger and more durable product.
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