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In recent years, with the development of the resin chemical industry, mould industry and automatic control machine manufacturing industry, the application range of injection moulded products has been widely promoted and popularised. As the application range of various modified plastics, engineering plastics, and composite plastics becomes more widely used, and the requirements for the precision and complexity of plastic products become higher and higher, the selection of suitable plastic moulding machine for sale becomes more and more important.
Factors influencing the choice of plastic moulding machine for sale
Usually, the important factors affecting the selection of the injection moulding machine are the weight repeatability of the product, the position of the mould opening, the cycle time, etc. Therefore, the following information must be collected or possessed before the selection is made:
- The product: size (length, width, height, wall thickness), net weight and total weight, etc.
- Materials: raw materials or granulated materials and other materials and the proportion of broken materials.
Injection molding machine how to choose the model
After determining the product information, you can follow the steps below to choose the right injection molding machine:
Machine types & series:
Decide the machine type and series according to the product and plastic. When the customer chooses the injection molding machine, the first thing to do is to determine the structural shape of the injection moulding machine according to the product take-out direction and mould structure: Vertical plastic injection molding machine, Angle moulding plastic machine, or Horizontal plastic moulding machine for sale. There is not much difference in the structural shape of molding machines from major manufacturers, and the structural difference is mainly in the mould clamping structure.
Wide range:
Due to the wide range of plastic molding machine, first of all, we should correctly judge which injection molding machine or series should be used to produce the product, such as ordinary thermoplastic or bakelite raw materials or PET raw materials, such as single-color, two-color, multi-color, sandwich or mixed-color. In addition, some products require high stability (closed loop), high precision, high injection speed, high injection pressure, or multi-loop (multi-circuit), and other conditions, it is also necessary to choose the appropriate series.
Selection of clamping force of the injection molding machine
Clamping is determined by the product mould design and construction and plastic to determine the &#;clamping force&#; tonnage. Clamping force is an important parameter of the injection molding machine, when the high pressure of the plastic melt is filled with the cavity, will produce a large expansion force in the cavity, so that the mould along the parting line expands. In order not to allow the mould to expand, the plastic moulding machine for sale must provide a force greater than this expansion force to lock the mould, otherwise, it will produce the phenomenon of overflow and runaway material, this force is the clamping force.
The clamping force is too large, not only will increase the customer&#;s purchase cost, but also will increase the wear of the mould and the cavity exhaust difficulty, so that the products will produce burnt or lack of material phenomenon; more importantly, when the machine is stressed, so that the machine wear intensified, shorten the life of the clamping mechanism and the hydraulic system, it will also cause a waste of energy, Therefore, when calculating the clamping force, we should use the projected area of the customer&#;s product and the ratio of process length to wall thickness, the material, and the cavity pressure of the mould to calculate the accurate clamping force. Clamping force and injection volume, to a certain extent, reflect the size of the machine&#;s ability to process products, which is often used as the main parameter to indicate the size of the machine specifications.
Choose the right type of injection moulding machine according to the mould
From the mould size to determine the machine&#;s &#;column pitch&#;, &#;mould thickness&#;, &#;mould size&#; and &#;mould plate size&#; is appropriate to confirm that the machine is suitable. To confirm whether the mould can be placed appropriately.
Connecting column (also known as guide column):
The internal distance determines the width of the external dimensions of the mould, the guide column can accommodate a large distance of the mould is also large, the guide column can accommodate a small distance of the mould is also small. Mould and template minimum contact area can not be less than 60%, and the maximum effective area of the mould can not exceed the area of the connecting column in the distance, otherwise easy to motor template force is not uniform, the product locally produced flying edge, the template is easy to crack.
Mould size:
The template is supported behind the mould ductile iron plate, the mould should not exceed the area of the template&#;s internal distance. To prevent the mould from bending during injection. Mould is too small and will produce too high bending stress on the template, and even make the template fracture. Injection of thin-walled products, high injection pressure, injection speed, cycle time is short, the template should be thickened, reinforced rib plate to strengthen, used to increase the rigidity.
Mould capacity:
The injection molding machine can accommodate the smallest to the largest mould, the difference between them is the moulding plastic machine mould adjustment. The available mould thickness should be greater than the minimum mould capacity so that the injection molding machine can open and close the mould. If this is not the case, special engineering work is required (the effective mould adjustment thread of the guide column is increased and the minimum value of the programme is changed). Similarly, if the available mould thickness is greater than the maximum mould capacity, special work is taken into account (the frame and the guide column and their threads are lengthened, the steel belt for moving the second plate of the frame clamp is lengthened and the maximum value of the programme is changed).
However, there is an upper limit for increasing the mould capacity and it is necessary to take into account the load capacity of the guide column (maximum mould load capacity). The maximum and minimum mould capacity of the machine dumpling type moulding plastic machine is the distance between the movable and fixed templates when the machine dumpling is straightened and the mould is set to the maximum and minimum respectively, this parameter determines the size of the mould opening space and the depth of the products. This parameter determines the size of the mould opening and the depth of the products. If the mould capacity is large, the depth of the products will be deeper; if the mould capacity is small, the depth of the products will be shallower. The fully hydraulic large two-platen moulding plastic machine has a larger mould capacity and mould opening stroke than other machines in the same class, which is more suitable for deep-cavity products and products with a high height.
Plastic injection molding is a manufacturing process with the principle ability of handling extremely large amounts of bulk parts production. It is important to note, however, that there are several processes when it comes to plastic manufacturing. Many companies also prefer this method over others, and because of this it affects other business sectors, such as pharmaceuticals and hospitals.
In today&#;s global economy, plastic has become well ingrained as an intrinsic sector in the world market. More and more businesses are constantly in search of the most reliable and cost-efficient method for generating their products and optimizing revenue streams.
This article offers a general overview that covers the basic surface-level skeletal structure of everything that goes into the economics of plastic processing, but ultimately focuses on injection molding and serves as a guide to understanding all the operative cogs that go into the process and the many ways in which this method can assist in boosting accumulative efficiency.
When it comes to plastic manufacturing there are intertwined and integral factors that go into considering the most fitting method for your purposes: The Form in which the shape of the final product is desired, the Budgeting of resource cost added with manufacturing parts cost, the Volume of the targeted total quantity, the Time of manufacturing that adheres to an approximated ideal deadline, and the Material which depends on final product output and desired method of manufacturing in relation to the other aforementioned factors.
The synthesis of all these factors is important because it dictates the direction in which you take your output line approximation by delineating the most appropriate method of production. Before we move on, we first need to cover the general types of common plastic formulas used in production:
Polyethylene &#; High Density, Low Density, or Ultra-High Molecular Weight, this material covers a wide range of durability levels; everything from plastic bags to cleaning bottles to bulletproof vests.
Polyethylene Terephtalate &#; Polyester fiber is usually utilized for apparel purposes. This more environmentally sound as light plastic is also recyclable in its substance.
Polyvinyl Chloride &#; PVC is commonly known as an industrial and construction plastic, but its versatility can also be used in the making of furniture, cables, and vinyl records.
Polyamide &#; Widely known in its pseudonym Nylon, this plastic is utilized for its flexible edifice; durability levels extend to ropes, cables, and heavy-duty machinery.
Polypropylene &#; This plastic formula is very adaptable and relatively low in cost to produce. The high melting point makes it more suitable in the production of food containers.
Polystyrene &#; Commonly known as Styrofoam, this plastic is repeatedly used to protect certain items from impact damage. Expanded Polystyrene is often used as padding.
Acrylontirile-Butadiene-Styrene &#; ABS is a plastic that is widely available and invulnerable to corrosives of a chemical nature.
Polyoxymethylene &#; Acetal&#;s plastic formula, after the molding process; reinforces and secures that a product keeps its initial shape. This product is normally used for cogs and various mechanical gears.
Polyurethane &#; This plastic is exceptional in its flexibility and versatility. Highly durable yet soft in texture; it can withstand even the harshest of conditions. Polyurethane material is also used as material for skateboard wheels.
Polycarbonate &#; Usually used as window type material, its transparent nature and high durability is made as the material of riot shields.
Acrylic &#; Similar to Polycarbonate in their transparent elements and high impact nature, this plastic can also be used for screen type gadgets.
Different Plastic Manufacturing Processes
This section provides as an illustration that outlines the different methods of plastic product manufacturing divided by quantity sizing, and identified by source material and tools.
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Low Volume
These methods operate on a more of purely grinding and cutting procedures for shaping.
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Fabrication
The product shaped with a non-digital process of carving, welding, and gluing.
CNC machining
A block of material is computer controlled, and the product is shaped through a series of drilling and grinding.
3D Printing
Plugged into a computer is a 3D Model, and the machine shapes the product through structure printing.
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Medium Volume
For Medium Volume and higher quantities of the required output, the molding and shaping is the most effective and necessary procedure for manufacturing.
Casting
Thick parts and wall sections are very possible outputs, however, this entails a lengthier production time of solidification post-cooling of mold.
Thermoforming
Sheet plastics are heated and vacuumed onto a mold. However, it is limited in shape due to only being determined by a single-sided-mold.
Rotational Molding
Molten formula is poured into a large mold and rotated until the formation of a hollow shape.
Compression Molding
2-part mold with heat and pressure processing, but only complies to limited shapes.
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High Volume
High volume outputs require more highly industrial methods that incorporate large machinery in its mass production scale.
Extrusion Molding
Similar to a sausage mincer, the plastic formula is seeping through a die and comes out into a steady length of the final form.
Blow Molding
A pre-fabricated tube pushes slightly molten plastic by blowing hot air into it and forming a mold.
Injection Molding
The injection of plastic to a 2-part mold, cooling and solidifying warrants a laser sharp precision when it comes to shaping.
Why Choose Plastic Injection Molding (Over Other Processes)
There are many reasons for going with injection molding as your chosen process in plastic manufacturing. First off, it continually proves to execute absolute accuracy with its consistency of detailed features. High precision in handling prototypes of complex geometry is done so in a fast and highly efficient manner.
Another major reason is the enhanced strength and flexible qualities of the post-mold product. It&#;s a resourceful method with the high strength components of its machinery. It also carries the means to deal with diverse plastic types simultaneously, and because of its power in Co-injection molding, it can handle varieties. It holds low scrap rates and is rapidly repeatable in nature.
Finally, it is widely used and arguably the most popular method because of how much it saves overall manufacturing costs through its low labor costs. In the long term scheduling operations, it greatly saves on costs in contrast to plastic machining. Not to mention, how it is also an environmentally friendly means of mass producing.
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What is Plastic Injection Molding
Injection molding is a manufacturing process with the principle ability of handling extremely large amounts of bulk parts production. With the utilization of an injection molding machine, here are the 6 major steps that surmise the entire injection molding process:
- Clamping
- Injection
- Dwelling
- Cooling
- Mold Opening
- Removal of Products
The initial jumping off point for any injection molding project is always part design. The other major factor that comes to play in the injection method is the mold&#;the hollow and formulaic substance that would later be manipulated into the desired shapes. It fills the machine&#;s cavities; and finally takes form in the cooling process. The building of the mold is a huge component that dictates the overall material quality of the final output. Testing the mold means a scrupulous monitoring of the molding condition. Often times, it is the case that manufacturers further boost efficiency levels by using reprocessed materials.
Before beginning with the actual mechanical procedures, the final configuration for manufacturing process and colors are finalized before execution. Injection molding machines are segregated into a clamping unit and an injection unit. The injection unit essentially is in charge of heating plastic to a molten degree and then inputs the mold. Speed controls and pressure controls are then calibrated to a certain fixed value. The final fine tuning of mold and materials means the machine is ready to do its magic.
How It Started
The development of Injection Molding technology dates back to the invention of plastic substance itself. In , the first condensation polymers were produced. John Wesley Hyatt&#;s introduction of the plastic derivative Celluloid reinvented the global manufacturing market. Hyatt, together with his brother, would later go on to construct the crude yet innovative prototype for the first ever injection molding machine in .
Early in the 20th century, the invention of Bakelite gave rise to the everyday usage factor of plastics. Leading to the s, the invention of major vinyl thermoplastics such as PVC and Polystyrene makes its way to becoming household essentials, even in the current day. With the rampages of World War II going on, the world&#;s industry sectors needed to call for cheaper means of mass production; leading to the breakout wonders of Nylon in . From to the mid-50s saw the transition of Polyethylene to Polycarbonate. And the widespread use of injection molding methods in the s set for gas fueled and assisted injection molding process.
In , Japanese firms broke out with the premiere of purely electric molding machine; and when rolled around, Aluminum molds widely used in injection molding. To this contemporary day, injection molding has firmly planted its roots in the world&#;s economic trade.
Common Products
Literally everywhere you turn, it&#;s impossible not to find any consumer products that haven&#;t been made with the mass producing constructive abilities of injection molding.
Everything from automotive bumpers and dashboards to virtually every type of lid is produced in bulk through injection molding.
In the average household, electrical switches and CDs&#;central technological systems are built from the reliability and consistency of injection molding. The everyday demand for medical supplies in the Healthcare industry is also supplied by the mass production prowess of injection molding.
How to Design Cost Effective Plastic Injection Molding
When it comes to reinforcing cost effectiveness in the process of injection molding, its key to constantly keep in mind one of the main pros of the manufacturing method: bulk production.
Here are some points you need to remember when undergoing bulk production:
- Optimize plastic part design by focusing on design modifications before the actual processing.
- Improve molding by remembering to choose designs that only require minimal materials.
- Ensuring an adequate draft means putting great consideration into part size when analyzing structural requirements and reducing solid part areas.
Always remember to produce the maximum quantity with as little time as possible. Reduce tryout times by minimizing secondary processes and getting rid of superfluous features. Make sure to use core cavities during production; and make notes to reduce cosmetic finishes and appearances.
In the final cooling stages, eliminate undercuts for a more efficient mold&#;build. The major takeaway here is to always keep things as simple as much as possible.
In terms of purchasing mold materials and standard parts, guarantee that you&#;re only using qualified plastic parts and materials that strictly meet your needs. For long term fortitude in cost efficient molding, always keep design longevity in check; use family molds (multi-cavity). Keep in mind that It can only be beneficial to modify and reuse molds. With all this being said, don&#;t forget to only choose a consistently reliable shop.
Common Mistakes in Plastic Injection Molding and How to Avoid Them
Although injection molding is an almost completely seamless process of mass production, it also carries within it a methodology that requires a practiced and trained skill set. Thus, it&#;s normal to run into a few troubles in initial runs, but remember that mistakes can cause a big dent in costs. What&#;s important is to always practice preventive measures and learn. Here are some of the common defects that can still possibly be remedied: Flow Lines, Sink Marks, Vacuum Voids, Surface Delamination, Weld Lines, Short Shots, Warping, Burn Marks, Jetting, and Flash.
In order to avoid these common mistakes in injection molding, it&#;s necessary to do everything in your power to facilitate the occurrence potential symptoms by making sure of proper design, size, and location of materials and tools. Improve proper wall thickness and design to avoid running into the labelled and aforementioned troubles; use textures because adding gloss will cover up and prevent mistakes that would be costly to mitigate design for stress avoidance, failing to do so may lead to major cost spikes.
Current Trends in Plastic Injection Molding
The splash Injection Molding makes on the waters of manufacturing technology sends ripples to every major material market; medical devices, for instance, are decreasing in size and at the same time, improving on the front of effectiveness. In the current world of thriving minimalism in almost every aspect of everyday life, automotive parts are becoming lighter in weight; this means that consumer electronics are seeing innovations on every front.
Plastic injection molding companies are a tight-knit group that support each other. We would like to thank the Feedspot blog for including our site for the top 40 Blog Plastic Blogs and Websites for Plastic Industry Professionals.
Global Distribution of Injection Mold Products from China
Capably navigating the complexities of plastic manufacturing, China has emerged as a leader in the injection molding industry. Expertly utilizing advanced techniques such as plastic overmolding, Chinese manufacturers produce durable, high-quality products, distributed globally. Significant among these markets is the USA, which benefits from China&#;s efficient, cost-effective production scales. Consequently, China continues to influence the international standards for plastic mold production and distribution.
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