Plastic Injection Molding Technology

Plastic die mould is a highly efficient and productive way of producing plastic products with complex designs and different thicknesses in large volumes. Injection molding of plastic takes place into a mold. It happens in a plastic product making machine that produces millions of identical products a year. Thus, injection molding is ideal for high volume production of plastic housings, parts, equipment parts, etc.

For the production of plastic products, contact a professional company. Only a reliable plastic die mould company can guarantee you the reliable products. .

Injection molding cost

The cost of plastic injection molding depends on the complexity of the preparatory stages and the design features of the future mold. Subsequently, the price of injection molding of plastic starts from $3933. Furthermore, it includes all the design and manufacture of the mold, as well as the cost of the first test casting.

Equipment for the manufacture of plastic products

To get injection molding, three things are important:

1. a plastic injection mold
2. an injection molding machine and
3. a plastic bag

Plastic in the form of granules or powder is comes into the dispenser, melted and fed into the mold.

At the same time, the punch (the movable part of the mold) closes with the die and the product appears. After that, it cools down and pushed out of the mold by a system of pushers.

 STAGES OF PLASTIC INJECTION DIE MOULD TO ORDER

Mold design and 3D modeling

In order to start the production of plastic die mould, it is necessary to make a mold. Therefore, it all starts with building a 3D model of the future product. Basically, it is the main foundation of the model. It must exactly repeat the outlines of the product, as well as rationally consume material.

When designing a mold for plastic injection, engineers need to choose the optimal cross-section for the product. Moreover, they need to think over the layout of the cavities, the device of the gating system and auxiliary systems.

It is necessary to consider the wear of the mold and the characteristics of the loaded materials. Hence, an improperly designed mold will waste materials and quickly fail.

A good plastic die mould company should employs top industrial designers and engineers to maximize mold productivity. Furthermore, custom injection molding is the first step towards realizing your dream of owning your own business.

Injection die mould manufacturing

After modeling, the 3D model of the mold breaks down into separate components. Similarly, manufacturers make molds from high quality steel on special CNC machines in the tool shop. In addition, the precision of modern mold making equipment allows you to perfectly recreate a mold from a model.

After that, we can assemble all parts of the mold, a cooling system, pushers and molten material supply is installed.

Test casting

After assembly, the mold casts its first piece. Generally, the accuracy of the casting, the quality of the product obtained. And we need to check the material consumption, etc.. Typically, the test casting includes up to 200 iterations, which should reveal the slightest defects.

Modification of the injection mold

In case of revealing defects in the work of the mold or in the cast products, we send the mold for revision.

Manufacturing of plastic die mould

When plastic die mould manufacturer takes account of all the nuances and the shortcomings of the mold have been corrected, it’s time to start your production! To do this, you need to install the mold the on an injection molding machine, connected to its “life support” systems. And it begins to produce a specified number of products per year.

ADVANTAGES OF INJECTION MOLDING

Low cost per item

Due to its high cost, injection molding is common for large-scale production of parts or products (from 1000 pcs). Similarly, each subsequent casting reduces the cost of products. And the price of one part from a large batch with millions of plastic products will be just a couple of cents.

The ability to manufacture complex products

Production of products by injection molding allows the production of small parts of various thicknesses and complex configurations.  The use of multi-cavity molds can increase productivity several tens of times at once (for example, in the production of handles). In addition, special mold parts – inserts – make it possible to immediately produce parts with holes, recesses or bulges.

Low probability of plastic die mould

The entire plastic die mould process comes into automation, which eliminates the possibility of operator error. As a result, we get the required number of products in exactly the same excellent quality.

No post processing needed

The injection molding process involves the production of a finished plastic product that will not need additional processing.  Even we can decorate with built-in threads.

Unlimited items

Generally, the number of press cycles is not limited. Once you order a mold, you can use it indefinitely, replacing parts as they wear out. Additional chrome plating of the mold will protect it from aggressive materials.

High quality

The quality of the products is at the highest level. Moreover, there is no flaws on the surface of the products, no roughness, brittleness or porosity.

Wide range of materials

When ordering plastic injection molding from plastic die mould specialist, you can choose the most suitable type of plastic and its color from a wide range.  Similarly, you can also order transparent plastic molding.

APPLICATIONS OF PLASTIC INJECTION DIE MOULD

Areas of use

Injection molding is appropriate for large-scale production and it is impractical to use it for the manufacture of only a few products.

In general, molding is common in all areas where you need to produce a  large number of the same plastic products.  For example, for the manufacture of:

• plastic containers
• plates
• Bottles
• children’s toys
• medical equipment
• office supplies.

Also, plastic molding into molds is applicable in mechanical engineering and rocketry, for construction purposes, etc.

MATERIALS FOR THE MANUFACTURE OF CUSTOM-MADE PLASTIC PRODUCTS

Types of plastics

For the manufacture of plastic products, thermoplastics and thermosets are very common. The former are recyclable, since they lend themselves only to physical transformations during the formation of the product. Moreover, reactoplastics undergo irreversible changes and turn into solid infusible materials. There are two types of injection plastic die mould, depending on the type of plastic.

Injection molding of thermosetting plastics

Basically, most often it is used to obtain massive and thick-walled parts. In this type of casting, the prepared material injects into an incompletely closed mold. It closes completely at the end of the injection. Products made of thermosets have an improved surface.

Injection molding of thermoplastics

The intrusive method of forming products consists in the fact that the plasticization of the product and the injection of the material combines. In this case, it is possible to obtain castings with a larger volume than the nominal injection volume.