It is a manufacturing process in which resins of plastic are injected in mould at high pressure in molten form. After the molten mass is cooled, it will gain shape of mould. This process yields plastic of tight tolerance and has low cost per part. There are verity of resins and adhesives available for plastic manufacturing and their use depends upon application in various parts.
The process of plastic injection moulding uses a tool to form part known as injection mould. These tools are customized according to the geometry, size, shape, cooling method and pressure of injection for a specific part.
The injection mould is injected with a molten plastic resin while keeping the mould clamped to a moulding press machine. The process involves injected of molten plastic, cooling the mass and finally taking out the plastic in hard form.
The overall cost of the mould really depends upon many factors such as design, complexity, size, materials and cavities in the mould. It can range from few thousand to hundreds of thousands depending on, size, complexity and type of mould.
The time required to build an injection mould depends upon complexity and availability of materials needed to build that mould. Complex moulds can take few months to complete from design to sampling.
Typical lead time ranges from 3-5 weeks but it depends upon many factors that can affect the lead time for a particular mould including availability of materials, size and complexity of mould.
The use of materials depends upon the application of plastic part. Some materials used for plastic injection moulding are as follows:
- Pre-hardened tool steels:
P20, NAK 50, NAK 55, NAK80 (lens grade Pre-hardened steel)
- Heat-treated tool steels:
H13, Stavax, Ramax, S7, 420SS
Some benefits are given as:
- High strength to weight ratio
- Corrosion resistance
- Increased toughness and structural strength
Some drawbacks are as follows:
- High initial cost
- Long lead time for manufacturing
- Design restrictions
These pins are employed to push parts out of the injection mould.
Some defects of injection moulding are:
- Short shot
- Splay marks
- Flow lines
- Sink marks
- Knit lines
- Burn marks (gas trap)
Some maintenance works are as follows:
- Cleaning of machine
- Replacement of hydraulic filters and cleaning of hydraulic filtration system
- Greasing of moving parts in injection machines
It is the plastic pressure at which the material is injected into mould through the nozzle. It is expressed in kg/cm2, PPSI or bars.
There are various types of plastic injection moulds:
- Rotary Shuttle moulds
- Vertical injection moulds
- Multi-shot injection moulds
- Stacked injection moulds (Stack moulds)
- Tandem injection moulds (T-moulds)
- Spinning Stacked injection moulds (Cube moulds)
Kore Industries Company Related Questions
Kore Industries has been designing parts and injection moulds for over 11 years. We are well-known for our customer-oriented service, and we believe in the integrity of our team. On top of that, our ISO certified quality products meeting the demands of the customers at the right time. We are also an approved tool vendor of General Motor (North America) and AITF 16949 certified for automotive moulding production.
The parts will be duly inspected, packed and arranged for shipment to the customer after the completion of manufacturing process.
Kore Industries assigns English-speaking project managers to our current and new overseas customers. You can reach out to your designated project manager to check on your project status. We normally update our customers on a weekly to a bi-weekly updates, depending on customer’s requirements.
Kore Industries designs and manufactures our moulds and mould plastic parts at our facility in Zhongshan, China.
Kore Industries has the ability to design and manufacture any part required for any type of moulds. Most of the works are completely done in our facility but some of the machining processes can also be done by our long-term prequalified vendors.
Kore Industries is the one-stop market for building injection moulds or moulded parts. We provide an automatic or manual assembly, and packaging options.
Kore Industries offers competitive prices around the globe. We design, store and distribute parts according to ISO certifications and helps the customers in reducing the overall cost and lead times. We are big on environmental sustainability and lowering cost through reducing of additional processes. Do find out more about our processes from us.
Kore Industries has its headquarter in Singapore and its manufacturing subsidiary in China. We also work with technical and sales consultants in Europe and America to better cater to our customers.
It depends on the complexity and availability of material for that specific component. However, simple moulds can take few weeks whereas complex moulds can take up to months. The time taken does not include any design changes as per required by the customers.
The cost of any plastic part depends on weight, size, shape, volume and cavities in the mould. Typically, small runs are more expensive because setting up and preparing the mould on the injection moulding machine will take time and money. Thus, bigger runs tend to help amortize the set up cost over the many parts, making it more economical per part.
Kore Industries is currently producing parts up to 16" x 26" x 40" in size. We have the specialization of producing small to medium sized parts.
Kore Industries has the capabilities to handle mid to high volume manufacturing. Minimum sized runs are treated as sampling runs and those would be charged a flat setup rate for its respective press size.
The standard lead time depends on many factors such as availability of materials and complexity of mould. However, typical lead time for simple mould of is 4 weeks and for complex moulds it can go up to three months.
Kore Industries engineers and designers play a key role in the manufacture of new products. We are open to and are frequently involved in early supplier development phases of the product development cycle, so we’re always able provide our customers our best DFM proposals early into the program in the design and manufacture of the new product.
Yes, Kore Industries works with different resins and pre-color compounds from the suppliers to get the desired color that the customer wants. We have had many years of experience with colour matching plastics to other materials such as fabrics too.
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