What is plastic injection molding?-Let Elite Mold manufacturer to tell you
Plastic injection molding is a production method used to create plastic parts and components in large batches. A pre-made mold is filled with molten plastic that is injected at high pressure into the mold. After cooling, the plastic is ejected and the finished parts are examined, packaged and shipped. Despite its efficiency in producing large quantities of parts in a short amount of time, the injection molding process must be carefully monitored to ensure the quality of the final product.
◆ What is injection molding?
◆ How does plastic injection molding work?
◆ How does an excellent plastic injection molding manufacturer control the quality of injection molding?
◆ You can pay attention to the following points if you want to find a plastic injection molding manufacturer.
◆ What is injection molding pricing?
◆ Advantages of Plastic Injection Molding process to mass production
◆ Different Types of Injection Molding Machines
◆What service can plastic mold manufacturer supply?
◆Lear More about plastic mold manufacturer
What is injection molding?
Plastic injection molding is a well-known manufacturing process used to mass-produce plastic parts. It involves injecting molten plastic material into a mold, where it cools and solidifies to its final form. Injection molding process is perfect for producing a high volume of plastic parts that are identical and consistent in size, such as plastic chair, plastic furniture, plastic boxes etc, even on intricately designed parts with low dimensional tolerance. The tooling process shapes the plastoc mold to the desired form as long as the tolerance is less than 0.01%, allowing for a range of applications that can be used in many industries and by individuals.
How does plastic injection molding work?
Plastic injection molding is a manufacturing process for producing parts from thermoplastic and thermosetting plastic materials. Theoretically, the plastic injection molding process may seem simple, there are many parameters which need to be tightly controlled to ensure the overall quality of the plastic components produced, such as plastic chair, plastic boxes, plastic furnitureetc.Let us understanding the plastic injection molding process and parameters in some depth will help injection mold manufacturers to identify plastic components producers who can provide the quality and as long as the tolerance is less than 0.01% they need.
Plastic injection molding can be performed with a host of materials, including metals, glasses, elastomers, confections, and most commonly thermoplastic and thermosetting polymers.
The plastic injection molding process quickly and accurately produces large numbers of parts, aslo can be performed with a host of materials, including metals, glasses, elastomers, confections, and most commonly thermoplastic and thermosetting polymers. Plastic injection molding is also wildy used to create many things such as wire spools, packaging, bottle caps, automotive parts and components, toys, pocket combs, some musical instruments (and parts of them), one-piece chairs and small tables, storage containers, mechanical parts (including gears, wheels), and most other plastic products available today.
The plastic injection molding process works by heating plastic material (ABS plastic, PC plastic, PA6 plastic, PP plastic, POM plastic, PBT plastic, PE plastic, HDPE plastic, PVC plastic, HDPE plastic, PET plastic, PPS plastic, TEFLON plastic, PMMA plastic, PU plastic, SMC/BMC plastic, PAI plastic, LCP plastic and PC/ABS plastic) to a molten state, then injecting it into a mold cavity under pressure. After the plastic has cooled, it is removed from the mold and the process is repeated. Plastic injection molding is typically used to create parts with complex geometries and high tolerances, as well as high volume production runs.
How does an excellent plastic injection molding manufacturer control the quality of injection molding?
The question of injection molding quality control isn’t if quality control is important, but really what does using the term ‘quality control’ mean? Plastic injection molding quality control starts with the specifications, and then the judging criteria against the intent. Dimensional stability, color, gloss, and molding defects define how well the product matches the intent, and if your consumer agrees your product is built with quality in mind.
Elt mold company as a excellent plastic injection molding manufacturer will control the quality of plastic injection molding by using high-quality materials(ABS plastic, PC plastic, PA6 plastic, PP plastic, POM plastic, PBT plastic, PE plastic, HDPE plastic, PVC plastic, HDPE plastic, PET plastic, PPS plastic, TEFLON plastic, PMMA plastic, PU plastic, SMC/BMC plastic, PAI plastic, LCP plastic and PC/ABS plastic), maintaining the proper temperature during the injection process to ensure the plastic is melted evenly, and inspecting the product for defects before and after injection. Elt mold company should also inspect the molds for wear and tear, and ensure that the injection process is being carried out correctly. We as a special injection moldig manufactuer, having a robust quality assurance system in place is also essential for ensuring the quality of injection molded parts for our coustom.
You must pay attention to the following 5 points if you want to find a plastic injection molding manufacturer to cooperating in china.
1. Check the plastic injection molding manufacturer's reputation: Before selecting a plastic injection molding factory, it is important to check its reputation in the China mold market. You can check the company reviews and ratings of the company online to get an idea about the mold company services.
2. Plastic injection molding experience: It is important to check the experience of the injection mold manufacturer in the particular injection field. An experienced mold manufacturer is more likely to provide better service and quality products.
3. Plastic injection parts availability: Make sure that the China mold manufacturer is able to provide timely services and can meet your coustom requirements in an efficient manner.
4. Plastic injection parts quality of after-sale services: You can check the injection parts quality of services offered by the China mold factory. Ask for references and read reviews to get an idea about the quality of services.
5. Injection mold Pricing & Cost: An excellent injection mold factory can save you purchase cost from the procurement of raw materials. Purchase cost is an important factor to consider when selecting a plastic injection molding manufacturer.
What is injection molding pricing?
Normally, the main cost driver in injection molding is the cost of the mold, you can choose a China mold mnaufacturer (such as elt mold company)if your want to reduce the injection molding cost. The cost of designing and building a mold depends on the required production volume, the complexity of the part design, mold material(Metal materials, plastic materials, ceramic materials etc), and the process used to create the mold.
Simple low-volume 3D printed molds can cost as little as $100 by our company, while the cost of designing and manufacturing complex molds for high-volume production may hit the $200,000 mark even more. Mold making despite the considerable fixed start-up costs, the injection molding process has low variable costs due to the inexpensive thermoplastics materials, short cycle times, and the labor needs decrease progressively due to automation and economies of scale. If it is achieved on the basis of mass production, the production cost can be minimized. This means that the variable production cost are low and the production process becomes more efficient and the cost per part decreases at higher volumes as the costs get distributed among hundreds or thousands of parts.
Advantages of Plastic Injection Molding process to mass production as bellow:
●Low scrap rates for product production
Plastic injection molding generates less scrap compared to traditional manufacturing processes and CNC machining. Excess plastics coming from the sprue, runners, and gates after the injection molding process may be heated and remolded if a recyclable thermoplastic material is used.
●Low production costs
Plastic injection molding is a highly automated process where most of its steps are performed by the machine controlled by an operator and intervention by manual labor is minimal. This reduces the plastic parts manufacturing cost.
The plastic injection molding process is a quick method of forming all kinks plastic parts. Regardless of size, regardless of product type, it can meet the requirements of mass production, the injection molding process has a fast production rate and is capable of producing voluminous plastic parts in a single cycle,. The mold may contain multiple cavities. The more cavities are contained in the mold, the more parts it can produce in a single molding cycle. Also, it can produce thousands of parts before the tooling needs to be maintained.
Plastic injection molding can produce multiple parts with consistent form and dimensions, such as plastic chair, plastic cup, plastic bucket, plastic autoparts, plastic medical devices etc. The parts produced in different molding cycles are guaranteed to be identical, all of the products tolerance can less than 0.01%. This advantage for injection molding process is necessary when product consistency is required.
Injection Molding Machines type, different Types of Injection Molding Machines
There are four types of injection molding machines, these including hydraulic, all-electric, hybrid and dual-color. Hydraulic injection molding machines are the most common type, as they use a hydraulic ram to inject plastic into the mold. All-electric machines use electric motors to move the components of the machine and are quieter and more energy-efficient than hydraulic machines. Hybrid machines combine the features of both hydraulic and all-electric machines. Dual-color injection molding machines are used to create products that are two-toned, let's discuss each of them.
1) Hydraulic Injection Molding Machines
Hydraulic injection molding machines are the most widely used type of plastic injection molding machine. They can inject molten plastic into a mold at high pressure and quickly produce large parts. These hydraulic injection molding machines are also relatively simple to operate and maintain, making them a good choice for businesses new to injection molding. But hydraulic injection molding machines do have some drawbacks, such as they tend to be noisy.
Hydraulic machines require a constant supply of pressurized oil, which can be an environmental concern. But based on the advantages of equipment cost and production efficiency, hydraulic injection molding machines remain a popular choice for plastic mold manufacturer that need to produce large numbers of plastic parts quickly and efficiently.
2) Electric Injection Molding Machines
Electric injection molding machines are other types of injection machines that are becoming more popular than other injection molding machines. It just has higher initial cost than the hydraulic counterparts machine, but they offer 2 advantages that make them worth the investment. Such as electric machines are more energy-efficient, that can resulting in lower operating costs. The second advantages, they also respond more quickly to changes in speed and pressure, making them ideal for agile production processes to the injection molding manufacturer.
Electric machines generate less noise and vibration than hydraulic injection molding machines, making them more comfortable to operate. As injection molding manufacturer continue seeking ways to increase efficiency and reduce plastic parts production costs, electric injection molding machine will become more widely used in injection molding factory.
3)Hybrid Injection Molding Machines
Hybrid injection molding machines are the latest development in plastic injection molding process. Hybrids combine the best features of both hydraulic injection molding machines and electric injection molding machines. Hybrid machines are more energy-efficient, saving money on utility bills then the other tow machines. They also more quieter and produce less vibration, the injection molding operators are very fond of using this equipment.
Hybrids offer greater precision and control than their hydraulic and electric counterparts, making them perfect for injection molding manufacturing applications that require tight tolerances.
Lear More about plastic mold manufacturer
Plastic mold manufacturer with rich experienc is specializes in supply free CAD drawing, prototype mold, 3D printing, mold design, mold making, moldflow Analysis, precise Machining, injection molding, free sample services, OEM services, ODM services etc. Whith plastic mold factory meet the following professional standards in hardware and software advantages, you can consider choosing them to supply the coustom mold servicess and injection molding services for you.
Mold design team
Which plastic mold manufacturer owns a professional technical team and precise equipment can better provides some plastic injection molding services, such as have more 20 engineers, Over 10 years engaged in the plastic mold industry, over 1000 industry products Mold making experience.
Have complete plastic mold production equipment and plastic injection molding production equipment
Casting equipment, Plastic mold cutting equipment, Plastic mold spraying equipment, Plastic mold testing equipment, Plastic mold processing equipment, Injection molding machine, Bag making machine, Plastic extruder, Cold press, Molding machine, Model machine.
Hight quality Injection Molding of Plastic parts
Which plastic mold manufacturer that can guarantee the quality of mold production must be have a complete plastic part production and mold making quality inspection process system.
1. Check the Injection Molding Machine for Proper Maintenance
2. Set the Correct Injection Pressure and Temperature
3. Use the Right Resin
4. Check the Plastic Part Design
5. Use Quality Molds
6. Monitor the Cycles
7. Check for Flash
8. Use Quality Control Procedures
Control production costs from raw material procurement
An excellent plastic mold manufacturer can start to save customers' costs from raw material procurement, mold design, uncle molding and other links. The specific methods are as follows:
1) Through use effective mold design methods to optimize plastic mold design, reduce plastic mold design redundancy, improve mold structure to the greatest extent, and improve mold production efficiency.
2) Choose the most suitable processing technology according to the plastic mold structure and requirements to reduce the plastic mold processing time and plastic mold processing cost.
3) Optimize the plastic mold material according to the requirements of the mold [polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), polyurethane (PU), polyvinyl fluoride (PVDF), polyester (PET), polycarbonate Ester (PC), ABS, polystyrene (PS), polyamide (PA)], choose the appropriate plastic material to reduce the material cost of plastic mold making.
4) Improve the plastic mold making process to reduce the cost of the mold making process. Commonly used processes include milling, wire cutting, spark machining, drilling, stretching, and surface treatment.
5) Improve the plastic injection molding process, reduce the consumption of plastic injection molding materials, improve product plastic parts quality, and reduce injection molding costs.
If you want to find a professional plastic mold manufacturer to supply you the coustom mold making services, welcome to contatc us today. Bellow is some of our company introduction to plastic mold service and plastic injection molding services, please check.
Software Simulation DFX
Coating (Painting, NCVM...)
Laser/Ultrasonic Welding Installation
|Injection Molding||Mold Development|
Cosmetic Part Molding
Two Color Molding
Gas Assistant Molding
In Mold Decoration
Liquid Silicone Molding
Mold Tryout& Fine Tune
On-site &On-line Tech Support
By co-operating with Elite Mold, you have selected one of the most reliable ISO 9001 certified plastic mold manufacturer, Elite Mold as a plastic injection mold manufacturer specializing in plastic injection mold and supplying plastic injection molding services for plastic mold design, prototype makings, mold flow analysis, precise machining, OEM services, ODM services and so on, building custom plastic injection molding. We are committed to enhance the Process optimized and quality of service, shorten lead time and assist in lowering inventory, by providing new products every year to bring in continuous and higher profits for our clients. The ability to produce mold at the International standard, strong engineering and mold design capability, aggressive delivery, competitive pricing and business integrity continues to be the success factor of Elite Mold.