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Injection Molding - A Comprehensive Beginners Guide

Injection Molding - A Comprehensive Beginners Guide

Injection molding is a robust manufacturing process used to make an enormous variety of products. It is a large-scale production method that is cost-effective for mid-volume production runs. In addition, it gives the manufacturer the ability to create complex items with fine detail accurately and efficiently. It is why injection molding has become so popular recently, as manufacturers are increasingly looking towards innovative processes to stay competitive in today's global market.

This process offers several advantages to manufacturers. To begin with, it is a highly versatile process for manufacturing all kinds of plastic parts. It is ideal for producing items that range in size from fractions of millimetres up to several metres in length and creating them with amazing intricacy and detail.

If you are new to this mass production process, then this comprehensive guide will walk you through the process.

How Does Injection Molding Work?

The principle behind the injection molding process is relatively simple. First, plastic pellets (or granules) are fed into a hopper which feeds them through a drill toward the injection unit. The auger then delivers the plastic to a heated cylinder, where it is melted and ultimately injected into a mould cavity at extremely high pressures. Once the material has been injected, the clamping unit opens and allows the part to be ejected from the mould. At this point, several runner systems divert a portion of material away from the main flow to other cavities so that multiple components can be produced at once.

The machine comprises three main components: the mould, plastic injection unit and clamping unit. First, however, we will break the components down to understand.

The Mould

It is where plastic is injected so it can form a part. It consists of two main components: A top half and bottom half, which are designed to clamp together. The mould halves are held together by bolts or screws, with a gasket in between the two halves to seal the process. Each part has its dedicated injection unit mounted onto the machine.

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The Plastic Injection Unit

It contains all components that melt and inject plastic into the mould cavity. The unit has a hopper, which feeds the pellets into the injection cylinder. From here, they are melted and forced under very high pressure through a nozzle at the tip of the cylinder.

The Clamping Unit

It is what holds everything together so that production can begin. The machine operator must set this up themselves before commencing production. The machine uses a hydraulic pump to pull the cam out of the way that allows the mould halves to open and close.

The Runner

It is a channel in which excess material travels from the injection unit so you can re-use it for another cavity assembly.

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Plastic and Rubber Injection Molded Parts for Automotive Industry

Source : Shutterstock(Licensed)

Plastic-injection-molding

Source : Unsplash

Injection Molding Considerations

Before you jump into injection molding manufacture, you need to consider some aspects to scale your business accordingly. Some key considerations are:

Financial Aspect

The initial setup cost of injection molding is higher than other forms of plastic manufacturing, but this is because it can produce medium to high-volume runs. Thus, you need to prepare a budget first before you plan to install this setup.

Production Quantity You Need

It's essential to figure out the regular production quantity you need, or you plan to meet post the machine installation. In addition, it will give an idea of whether having an in-house matching will be a cost-effective option for your business. Else, you can also go for injection molding online services.

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Design Factor

It's always recommended to design your components so that they are easily manufacturable. It will ensure you get quality products at reduced production cost. However, if you plan to manufacture products with very complex geometry, the overall production cost and time will increase.

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How To Reduce the Mould Cost?

Several new advancements in injection molding let you save operational costs and make products effective. Some of the essential tips for designing injection-moulded plastic parts are:

  • Eliminate Undercuts: The designer should always avoid undercuts that occur from draft angles, which can increase the cost of manufacture by as much as 30%.
  • Remove Unnecessary Features: You can remove features like bosses, ribs and large radii if they're not required to the part's function.
  • Use A Core Cavity Approach: The core is kept to a minimum while inserts construct the part.
  • Reduce Cosmetic Finishes: Finishes like plating and painting can add high costs, and you can avoid them if not needed.
  • Design Parts That Self-Mate: Parts that are designed to fit together without the use of fasteners can reduce assembly time.
  • Modify And Re-Use Existing Moulds: You can make several modifications that fit different product requirements when a mould is made.
  • Monitor DFM Analysis: A design for manufacturability analysis must be performed before designing injection moulds. It will help you understand the changes that need to be incorporated into the mould.
Injection-Molded-Plastic-Components

Source : Unsplash

Industrial injection molding

Source : Unsplash

When Is Injection Molding Ideal to Use?

Generally, injection molding produces large volumes of plastic parts in high production requirements. Therefore, it's suitable for mass production where you have some plastic product coming out of the machine frequently.

Many different types of plastics are available for this process, but it's preferred with thermoplastics rather than thermosets.

Types Of Injection Molding Processes:

  • Cube molding
  • Micro injection molding
  • Die casting
  • Thin-wall injection molding

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  • Liquid silicone rubber injection molding
  • Gas-assisted injection molding
  • Metal injection molding
  • Reaction injection molding

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Injection Molding Applications

Injection molding is employed in a wide range of applications across multiple industries. Some of the critical applications are:

  • Automotive —It's used to produce car body parts and interior fittings.
  • Medical — Used for creating medical equipment, implants and packaging.
  • Aerospace — Used to manufacture aircraft components such as avionics, nuts and bolts.
  • Electronics industry — Used in under-the-hood components like switches, battery covers and buttons.
  • Packaging — Used for manufacturing food and beverage packaging. It helps in forming corks, bottles and caps.
  • Houseware — Used to manufacture kitchen utensils, tableware and other household products.
  • Industrial equipment — Injection molding produces industrial automation machines such as conveyors, robot arms and robotic cells.
Industrial Plastic Injection Molded Parts

Source : Unsplash

Injection Molded Plastic Parts

Source : Unsplash

Advantages Of Injection Molding

  • Low cost per cycle
  • Flexibility in mold design for affordable customization
  • High-volume production rates when compared to other molding methods
  • Minimum scrap/waste generation when good material management is practised
  • Customizable products with short lead times

Wrapping Up!

Injection molding is a widely used process popular with manufacturers looking to produce parts in bulk. However, this method involves initial costs in setting up the equipment and time to design injection moulds. However, it has long-term benefits when it comes to high-volume production requirements. If you don't plan to set up your in-house equipment, you can also avail on-demand injection molding services from professional companies like Zeal 3D.

Industries and Applications

The following industries are the most ardent users of AM technologies in their businesses.

Automotive

Lightweight aerodynamics parts are desirable in the automobile industry. This contributes to making cars more energy efficient. 3D printing in the automotive industry is used both for rapid prototyping services as well as for some end parts creation.

Manufacturing

The precision and accuracy of 3D print processes are helping the manufacturing industry reduce material wastage, save time, money, and efforts.

R&D

Rapid prototyping has become a crucial component used in R&D departments of leading businesses. It helps save time and money for the manufacturers.

Medical and Healthcare

This is one of the most promising sectors for applications of 3D printing. Some of the applications include prototyping for product development to creating actual patient solutions, such as dental crowns, prosthetics, implants, human tissues, and organs, as well as 3D printed surgical instruments.

What is 3D Printing?

Architecture

3D architectural models enable businesses to showcase accurate details of projects. Architects also have greater design flexibility when they use 3D CAD models.

Aluminum 3D Printing

Jewellery

Lightweight aerodynamics parts are desirable in the automobile industry. This contributes to making cars more energy efficient. 3D printing in the automotive industry is used both for rapid prototyping services as well as for some end parts creation.

Aerospace/Defence/Navy

This industry was one of the earliest adopters of additive manufacturing. Rapid prototyping has become a critical component in the development of replacement and end parts in this industry.

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