Precision plastic injection moulding is an incredibly important part of multiple industries and understanding the injection moulding process might help shed some light into its importance in modern industries.
By knowing how it works, you will get a better idea of what you should expect when you next place an order with regard to precision moulding advantages.
What is Precision Injection Moulding?
In essence, precision injection moulding is all about the production of parts, housings, and brackets using a highly precise forming process and device.
Such a process typically makes use of a select type of polymer resin to make the necessary plastic part. However, composite materials and even metal are sometimes used as well.
The main point of precision injection moulding is to produce plastic parts that are of very tight dimensional tolerances.
Molten plastic pellets, called the melt, are injected into the mould, cooled, and ejected from the mould cavities.
What makes this particular process special is the precision level with which it can make plastic parts at large volumes and low costs.
As long as the mould itself is made well and the process parameters are stable and repeatable during the injection moulding process, the part is going to come out exactly as needed.
The process is fairly fast, as well, so mass production can be done quickly. At Kore Industries, we can easily accommodate demands of any size and schedule for plastic injected parts.
What Injection Moulding is For?
The purpose of precision plastic injection moulding is to create precision plastic parts efficiently where the melted plastic resins are injected into moulds made of steel.
Doing so will fill up all of the available space in the mould cavities and when the mould closes, it will cool down and take on the shape of the part needed to be subsequently ejected from the injection mould.
With regard to the full list of benefits of injection moulding, here are its biggest advantages:
- High precision - There is the obvious superiority in unit economics when injection moulding is compared to other precision manufacturing methods. The balance between costs and precision of the manufactured parts from injection moulding and this is one of the biggest reasons why it is a popular manufacturing method.
Parts for highly precise machines can be made in a relatively reliable and accurate manner.
- Highly repeatable - You will find no issue with how often parts are produced with this method and how closely the subsequent items mirror the first. What you want is exactly what you will get each and every time.
- Fast production - The production of parts using this method is extremely fast given how reliable the precision is and how repeatable the whole process can be. You can easily get as many mass-produced versions of items such as precision plastic parts such as a precision plastic gear as you need as fast as you need them.
- Low cost - Compared to other manufacturing methods, precision injection moulding is quite a bit cheaper due to the automated nature of the process and the minimal wastes in raw material.
- Versatile materials - The choice of materials in precision plastic injection moulding is actually quite versatile. There are many types of polymer materials that can be used to create gears, housings, and frames of any kind.
- High customization - In terms of the surface finish, color, style, and so much more, injection moulding is one of the best options in manufacturing. The customization is practically built into the moulding process.
- Reduced waste - Finally, there is the matter of waste reduction. With precision injection moulding, you only get exactly the size and shape of the parts you want. This process does not involve material loss in manufacturing of the item you want compared to other subtractive manufacturing methods.
As such, only the necessary amount of plastic or whatever other kind of material used is expended.
How Precision Injection Moulding Works
The process for precision injection moulding is fairly straightforward. We start by performing the Design-For-Manufacture or DFM of the part 3D model before design construction. Upon finalizing the DFM and tooling construction, we proceed to build the plastic injection mould.
Step 1: Creating the mould design
The design for the mould will need to be conceptualized so that potential issues and enhancements could be considered and incorporated into the mould design ahead of time.
Step 2: Fabricating the mould
Upon the finalizing of the mould design, the build process would commence. There will be numerous control points and quality checks on the mould components before they are all assembled into a functioning plastic injection mould.
Step 3: Mold sampling
Once the mould has been made, it would be sampled in a tool trial where specifics of the mould would be assessed. Items such as the cavities balance, the gate freeze, the part geometry, and the mechanical functionality of the mould itself.
Step 4: Mould cooling
There’s always a saying that there’s never too much cooling in a mould and there’s plenty of truth to that. With adequate cooling, the mould would be able to operate without seizing up due to overheating and thermal expansion of the steel blocks.
Also, with ample cavity cooling we are able to shorten cycle times and process warp issues commonly present in injection moulded parts.
Step 5: Part ejection
The final step is the extraction or ejection of the product. This is typically achieved by the moulded plastic article being mechanically pushed out of the injection mould cavities using numerous ejector pins.
Anyone interested in what we have to offer or learn more about plastic injection moulds, box builds, multi-shot parts, and many more can take a look at our line of Kore Industries services.