Plastic injection molds are usually made from hard and durable thermoplastic polymers that turn molten at high temperatures and solidify when they cool. Various additives may be mixed with these pellets to create different types of plastic parts.
Clamping pressure, injection pressure and holding pressure are important factors to balance when producing a plastic injection molded part. When these forces are not balanced correctly, quality issues can arise.
Recyclable
Injection molding uses either thermoplastic or thermosetting plastics to create a shaped product. The process involves melting the plastics before injecting them into a mold where they cool and solidify into a final product.
A variety of different types of plastics can be molded with this process, but some require specialized molds. Polycarbonate, for example, requires a special type of mold known as an injection molded polycarbonate (IMC) mold that can withstand high temperatures. Other resins that require specialty molds include elastomers, such as TPE and SAN.
Injection molding can use recycled plastics as well, which saves on manufacturing costs and helps the environment. Using recycled HDPE, for instance, allows manufacturers to cut back on the need for new petroleum-based plastic materials. It also reduces waste and closes the industrial loop. This can boost a company’s reputation among customers who care about environmental concerns. Ideally, the recycled material used in the injection molding process should be ground into small pellets that are uniform in size.
Durable
Plastic injection molding is a cost-effective and precise manufacturing process that can produce products in large quantities. It is also a durable production technique that can produce parts with high tensile strength, which is the amount of stress the material can withstand before it breaks. This is a significant advantage over metals, which can only withstand up to 4,000 psi.
The plastics used in the injection molding process include polyethylene terephthalate (PET), polypropylene, and acrylonitrile butadiene styrene (ABS). These materials are strong and lightweight, making them ideal for many applications. For instance, PET is a common choice for food packaging and medical devices. It can also withstand high temperatures.
Another popular plastic resin is acetal, which offers resistance to chemicals and corrosion. It also has a hardness that makes it suitable for cable insulation and sports gear.
Versatile
Plastic injection molding can be used to produce a wide variety of products. It is an ideal process for manufacturing large, complex components. It is also a cost-effective and efficient process for producing high-volume parts. It is a great option for companies that need to manufacture a large number of identical parts in a short time.
The plastic material used in injection molding can vary based on the product. In general, it should be tough and fatigue-resistant. It should also be resistant to chemicals and temperatures. Examples of suitable plastics include polyethylene, acrylonitrile butadiene styrene (ABS), and nylon. Some plastics are reinforced with glass or metal to increase their strength and stiffness.
Custom injection molded parts are very versatile and can be made to meet the exact specifications of the project. They are also precise, with tolerances that can be as low as 0.005 inch. They are also available in a wide range of colors and textures, which can enhance the look of the finished product.
Affordable
Plastic injection molding is a cost-effective solution for a wide range of industries. It can be used to create high-quality products and prototypes that can accelerate product development and reduce costs and lead times. It is also a great choice for complex designs that require tight tolerances.
Some common materials for plastic injection include polypropylene and polyethylene. These are inexpensive and can withstand a variety of temperatures, chemicals, and environmental stresses. They can be used to produce a wide range of consumer and industrial products, from milk jugs to car batteries.
The cost of the injection mold depends on its size and design. Smaller injection molds are less expensive than larger ones. The cost of a mold is further affected by the type of machine and material used. Injection molding machines can be divided into four basic types: hydraulic, electric, hybrid hydraulic-electric, and mechanical. Hydraulic machines are cheaper, while electric and hybrid injection molding machines offer greater precision.