The injection molding process requires the use of an injection molding machine, raw plastic material, and a mold
Yet many of us have no idea how plastic injection moulding works, or what’s involved in producing products.
Plastic injection moulding is capable of producing large volumes of high-quality, identical items in a short time. The technology is used in a wide variety of industries, including aerospace, medical equipment, and automotive so products that are produced range from precision engineering components to regular household items.
The variety of shapes, sizes, strength and types of thermoplastics that can be used in injection moulding mean that the process accounts for a significant proportion of plastic products produced today.
Most thermoplastics can be processed by injection moulding; the most common materials used include:
Consists of three main components:
Consists of three main components:
The first step of a product to be made by injection molding process is creating a mold. After a product is designed, usually by an industrial designer or an engineer, moulds are made by a mouldmaker (or toolmaker) from metal, usually either steel or aluminum, and precision-machined to form the features of the desired part. Once the mould has been created and thoroughly tested, it is ready to begin creating components.
The injection molding machines works by taking plastic powder or granules and manipulating it to shape it into a part according to the requirements and dimensions.
The whole process can actually be broken down into a few essential steps as below:
When the feed hopper receives the plastic granules, it then uses frictional action of the screw to create heat. Once the plastic reaches the correct temperature, it is then injected into the mold cavity, where it eventually cools and takes the shape according to the mold design. The mould tool is mounted on a moveable platen – when the part has solidified, the platen opens and the part is ejected out using ejector pins. After the mould then opens and ejects the newly formed component and the process is repeated.
The basic principles behind the injection molding process may seem simple, but in reality, it is a very complicated process that requires the right equipment and the right expertise. However, when it is executed correctly, injection molding can consistently produce excellent results even for the most challenging manufacturing projects.
Injection Molding machines are classified primarily by the type of driving systems they use: hydraulic, mechanical, electrical, or hybrid
Hydraulic process have historically been the only option available to molders until Nissei Plastic Industrial Co., LTD introduced the first all-electric injection molding machine in 1983. Hydraulic machines, although not nearly as precise, are the predominant type in most of the world, with the exception of Japan.
Mechanical type machines use the toggle system for building up tonnage on the clamp side of the machine. Tonnage is required on all machines so that the clamp side of the machine does not open (i.e. tool half mounted on the platen) due to the injection pressure. If the tool half opens up it will create flash in the plastic product.
The electric press, also known as Electric Machine Technology (EMT), reduces operation costs by cutting energy consumption and also addresses some of the environmental concerns surrounding the hydraulic press. Electric presses have been shown to be quieter, faster, and have a higher accuracy, however the machines are more expensive.
A robotic arm is often used to remove the molded components; either by side or top entry, but it is more common for parts to drop out of the mold, through a chute and into a container.
weight of product is too high, the product is too soft or too tough, there is spots on product surface etc
The main reason that manufacturers add CaCO3 Filler masterbatch into injection molding products is to reduce the production cost while maintain the good physical features of the final products.
For big size products, users tend to use CaCO3 Filler masterbatch at lower dosage than for smaller size products because when using this filler material, the weight of each unit will considerably increase and that matter is not preferred by the manufacturers. In general, the requirements of plastic raw materials for injection molding products are not strictly in comparison with those for other plastic products. The manufacturers tend to use Calcium filler masterbatch of middle to lower level of quality on the only condition that it can disperse well with other polymers in the composition.
Those manufacturers with good experience share that it is better to use the CaCO3 filler masterbatch with the Melt Flow Index similar to that of the base polymer using for the product to get the best operating results. To get this matter to be controlled, it’s better to consult in details with your CaCO3 filler masterbatch supplier. Here in US Masterbatch JSC, we are condident to provide you with the most suitable solutions for your injection molding products. With our experience, we will give advices and instruction to avoid those possible problem when using Filler masterbatch during production process, such as: indispersion, raw materials not fullfil in the mould, the weight of product is too high, the product is too soft or too tough, there is spots on product surface etc