Plastic Injection Mould and Moulding
- Our Experience in plastic injection mould and moulding (Gallery / Videos)
- Why Choose Kore?
- What is Plastic Injection Mould?
- What is Plastic Injection Moulding?
- Benefits of Plastic Injection Moulding
- What are the different types of plastic Injection moulding
- Areas it is best applied
Our Experience in Plastic Injection Mould and Moulding
Why Choose Kore
- We can handle manufacture of complex moulds and moulding very well because of our strong foundation in making single-shot plastic injection mould and moulding.
- We take strong pride in the fact that at least 90% of our customers have been with us since we started until today.
Find out more about single-shot plastic injection mould and moulding below.
What is a Plastic Injection Mould?
A plastic injection mould is a specialized kind of processing tool specifically used in the process of plastic injection moulding.
The moulds may be fixed or may have adjustable shape. These moulds are designed to withstand the severe conditions created by the interaction of the screw/barrel of plastic injection unit and the molten resin during plastic injection molding process.
Plastic injection moulds are constructed using special tool steel or aluminum with exceptional tensile strength, durability, thermal characteristics and material density.
So, what is Plastic Injection Moulding?
When raw material or plastic resin is heated to its melting point, simple and complex products of desired shape can be injection moulded. During this injection moulding process, the melted semiliquid substance is forced into mould of specific shapes where it (the material) cools down and forms the end product with the help of a plastic injection moulding machine.
The everyday plastic gadgets and items (well! most of them) are the products obtained from the moulding process. Household plastic items such as baskets, plates and casing and circuits of electronic items to more sophisticated multi-shots and multi-components plastic parts found in automobiles and consumer products are some of the very instances of products created by plastic injection moulding.
Procedure of the plastic injection process has been summarized and simplified in the following steps:
- Design for manufacture (DFM) are done prior to fix issues with the 3D CAD model of the parts to make the parts mouldable.
- After DFM, the 3D CAD model of the part geometry is rendered toolable the plastic injection mould design ensues.
- Sometimes prototype moulds are built before building the actual production moulds. The prototypes are first produced, tested before the manufacture of actual product from serial or production mould.
- Aluminum or steel is used to make the plastic injection moulds.
- When the mould build is complete, and there will be a mould trial which is commonly refered to as T0, T1 or FOT (first-off-tool) to see how the first parts look. Also, this is the time to review the quality and workmanship of the mould build.
- Raw material is fed to the feed hopper during the actual plastic injection moulding process.
- Plastic polymers will be converted from solid pallets to semi-solid state called the melt by the immense pressure created by the screw turning in the barrel during material plasticizing.
- The material is forced into the open chambers within the plastic injection mould by the injection screw of the moulding machine’s plastic injection unit.
- Finally, cooling of the product takes place. It is taken out of the mould after a specific period of time.
- Quality checks are then applied to the finished product and First Article Inspection (FAI) reports are submitted to the customer for review
Benefits of Plastic Injection Moulding
- Versatility of the plastic moulded parts in terms of colors, texture and geometry
- Complex parts could be manufactured in very high volumes at very low costs
- Products of great strength and other functional characteristics can be conceptualized and created by the injection moulding process
- Plastic injection moulding has excellent unit economics and quick volume ramp up capabilities by just building copy or capacity moulds for significant increase in demands
What are the different types of Plastic Injection Moulding?
- Single-shot moulding
- Double-shot moulding and A.K.A multi-shots moulding or multi-color moulding (Link to multi-shot moulding page)
- Over moulding and Insert Moulding (Link to over moulding and insert moulding Page)
What areas is it best applied?
The applications of the plastic injection moulding process can be observed in almost anything and everything that can be made of plastic.
Some of the examples are:
- automobile parts
- household appliances
- medical devices
- Housings for electronics
- farming tools
- packaging such as lip balm containers, caps, and so on.
- Daily use combs, caps of bottles, wire insulations etc.