Plastic injection molding

Plastic injection molding

Injection molding is a manufacturing process, which is making semi-finished parts of certain shapes by pressurizing, injecting cooling and separating molten thermoplastic.

Validate and optimize your tool design

Agenda

  • Challenges
  • Design phases
  • Simulation methods
  • Summary and question

Challenges

Many factors and decisions for molded components

  • Continual change

Part geometry, process type, material design, mold design

  • Application criteria

Function, cosmetics, volume, economics, life cycle

  • Variations

Lot-2-material, machine ware, machine cloning, mold ware

Process and analysis types

  • Gate location analysis
  • Molding window
  • Filling
  • Runner balancing
  • Fiber orientation
  • Packing
  • Design of experiment
  • Venting analysis
  • Crystallization analysis
  • Core shift analysis
  • In-mold label
  • Wire sweep paddle shift
  • Cooling and heating analysis…………steady state, transient, multi cycle, conformal
  • ‘repaid heating and cooling…………water, steam electrical or induction
  • War page and shrinkage analysis
  • Thermoplastic injection molding
  • Two-shot molding sequential, insert molding, over-molding, IMD
  • Gas-assisted injection molding
  • Injection compression molding
  • Bi-injection molding
  • Microcellular injection molding
  • Birefringence
  • Structural reaction injection molding
  • Rubber, liquid silicone injection molding
  • Multiple-barrel reactive molding
  • Reaction injection molding
  • Microchip encapsulation and underfill encapsulation
  • Export as-manufactured properties to FEA
  • Defect visualization

The Best opportunity for the design process

  • Part design

Concept, select material, prototype, estimate cost…..

  • Mold design

Quoting, concept, initial layout, during fabrication…….

  • Process development

Develop a stable process, optimize quality criteria, and minimize cycle time

  • Production troubleshooting

Oops…….. I did it again

Product development cycle

  • Lower costs through upfront insight into the part and mold optimization
  • Reduce time to market and avoid warranty issues and recalls
  • Have confidence that the design is the right

Part design

DFM

Normal wall thickness

  • Thickness variation
  • Traffic-light display
  • Plastic design rule: thickness changes no more than 30% of nom. Wall thickness

Draft angle

  • Draft variations
  • The Draft is acceptable locations

Undercut

  • Suitable undercuts

Molding window analysis

  • Take the guesswork out of your process window

Helps determine process window and optimum conditions

  • Full range of  plastic mold, melt temperature
  • Pressure limit
  • Temperature drop through part

Define the size of window by

  • Number and location of gates
  • Per geometry
  • Material – can compare several materials

Mold design

  • Runner system
  • Venting
  • Steel types
  • Cooling and heating

Cooling and heating

Revised design

  • Range 72 – 105 degree
  • Difference 33 degree
  • Average tem 89.1 degree

Original design

  • Range 55 – 119 degree
  • Difference 64 degree
  • Average tem 88.2 degree

Variable coolant inlet temperature and coolant during a cycle:

  • Heating phase
  • Air purge
  • Cooling phase
  • Air purge

Mold heated by:

  • Water, steam, electrical or induction

Heating and cooling phase:

  • Time or temperature (thermocouple) controlled

Summary

The design is the choice of your

  • Mold design
  • Part geometry
  • Process type
  • Material

Validate and optimize your design

  • Part simulation
  • Runner simulation
  • Venting simulation
  • Cooling and heating simulation
  • Design of experiment

Important Facts About Custom Mold Products

Pet products have brought big changes in commercial, residential or industrial terms. Products are printed according to specified requirements. Molding can be done in all types of materials including rubber, plastic molding parts, glass, metal, ceramics, thin-wall molding or other materials. With sophisticated techniques and sophisticated mechanisms, there are several companies offering pet products that serve various China printing industries across the spectrum of fields. These products are very real and are made from higher quality raw materials. Get the most out of the product and get different benefits.Plastic molding parts

Pet products can be customized and are more effective in terms of efficiency, durability, and reliability. Specialized products can make a big difference in all types of industries and implement better performance and great ways to work with market needs. The advantage of a special product is that it witnesses immediately after its execution and installation. From rubber grommets to metal forms used in aviation and other requirements of large-scale manufacturing, the importance of custom-made products is felt everywhere.

Injection, compression, and transfer are some of the additional methods applied when custom printing various products. With extensive expertise in design and engineering, specialty products are the best in terms of production flexibility. Castings can be produced in various shapes, sizes and other dimensions that can be modified according to specific needs. Consider the core demand for this problem to try and decide that further helps you find the best solution for clients and customers. Manufacturing custom-made products require extensive knowledge and experience to provide the best products at cost-effective prices.

In addition to quality, the technique is also important and therefore it is very important to choose a manufacturer of molded products that are made wisely. Every detail can be evaluated and checked via the Internet. Get the most out of it and make sure that the distributor or manufacturer gives you the best offer at a lower price.

Molding can be done in all types of materials including rubber molding parts, plastic parts, glass-fiber parts, metal, ceramics, thin-wall molding or other materials. With sophisticated techniques and sophisticated mechanisms, there are several companies that offer mold products that serve a variety of China mold industries across the spectrum of fields. This mold product is very effective and made from superior quality raw materials. Get the most out of the product and get different benefits.

Some Plastic Molding Methods

Plastic is widely used by several different manufacturers because it can be printed easily. There are several common methods of plastic molding. Here are three commonly used plastic molding methods.

Blow Molding

This plastic molding method starts by melting molten plastic in the machine room and then sending the liquid plastic to the mold to make the desired shape. Blow molding specializes in creating Hallow products such as bottles, motorcycle fuel tanks, hoses, bumpers, and several other hollow products. In addition, the final product is smooth. The main process of this method is that air is blown and locked to create holes. When liquid plastic is poured into a mold, the plastic will harden so you can make the shape you want. Then, you can remove the mold through the mold cavity.

Plastic Mold

This type of method uses thermoplastics. Among other methods, this is more often used by manufacturers. Methods include firing thermoplastic hot liquids at high speed into ceramic molds. Then, the mold is tightly bound while the plastic will follow the shape of the mold. The plastic will be cooled by small vents on each side. When it is cold, it is removed and then painted. However, this method leaves fewer stitches so that the final product will be finished for better results. Products made through this method include toys, MP3 player boxes, car dashboard casings, and several others.

Thermoforming

This method focuses on making larger items that are mainly used for industrial use and home furnishings. This method is quite simple. You only need to heat the plastic until it is soft so that it can be manipulated to create the desired shape. Then, the small machine will add any detail to things like body polishing, decoration, and also tracking the stamp. Common products from this method include aircraft windshields, truck beds, industrial pallets, and several other large items.

Plastic is one of the main materials for several manufacturers. Plastic manufacturing products have been widely used by most customers. Plastic products that are commonly used include car bumpers, cell phones, incubators for babies, and several other items for both household and industry. Each of these products might require a different method.

New Owner to Help Synventive Reach Goals in Its Five-Year Growth Plan

Synventive Molding Solutions,a world-leading designer, manufacturer, and supplier of custom process-improvement systems and related components for the injection moulding industry, has been acquired by Advent International, a global private equity investment company headquartered in Boston, Massachusetts, USA. Purchasing the company from Madison Capital Partners, Advent International will support Synventive in its five-year growth plan by providing financial and strategic resources to enable it to grow both organically and through possible acquisitions.

Synventive has multinational headquarters and factories in the United States and the Netherlands, with additional manufacturing facilities in China and Germany. The company employs more than 550 people worldwide and has a global network of sales offices that provide sales and service to customers in more than 50 countries.

The acquisition by Advent International is expected to enhance Synventive’s long-term value by allowing it to continue to focus intensely on customer needs and product innovation in its core specialty of hot runner control technology.

“Synventive will continue with its current strategy, which is to become the supplier of first choice to the plastic injection molding industry,” said Synventive president and CEO Dale Barnhart. Efforts to develop new products, shorten delivery cycles, improve product quality, and seek ways to increase the value of its systems to plastic-injection moulders will be paramount, Barnhart added. “Just as important, we will also continue to enhance our sales, application engineering, and postsales service support.”

Synventive will continue to expand its geographic reach. The latest example of this intention is the new facility the company opened in China, which began production in August.

Enterprise Planning Software Firm IQMS Launches Full-Scale European Enterprise

The globalization of manufacturing is driving business opportunities for California-based IQMS, the developer of EnterpriseIQ enterprise resource planning (ERP) software for repetitive, process, and discrete manufacturing environments. In 2004, 25% of the company’s growth came from elsewhere than the United States. Consequently, the company has officially launched IQMS Europe, which folds its exclusive distribution partnership with Plasticsgrid into the IQMS global organization.

IQMS and Plasticsgrid teamed up in 2002 to deliver the EnterpriseIQ system to manufacturers throughout Europe. A third party provided implementation services. Now, with IQMS Europe, one company will provide sales, marketing, implementation, and service to European customers. The consolidation strengthens the ERP provider’s overall position in Europe.

“IQMS Europe enables us to offer our customers a complete service with enhanced support and implementation services,” said Ola Gejde, managing director of IQMS Europe. “Our knowledge of the precise needs of manufacturers helps customers achieve faster implementation time and higher return on investment with EnterpriseIQ. EnterpriseIQ gives manufacturers the ability to manage their operations across multiple plants, multiple languages, and even multiple currencies with one comprehensive system.”

Plasticgrid has offices in Stockholm, London, and Kapellen, Belgium, and its managers in those locations have a combined 75 years of manufacturing, plastics and chemicals, and information technology experience. Their expertise gives IQMS Europe a strong understanding of the specific needs of manufacturers in the plastics, automotive, medical, and other industries.

One in four new IQMS customers last year were outside the United States. Earlier in 2005, the company formed IQMS Asia and opened its first office in Kaohsiung, Taiwan. A second IQMS Asia office recently opened in Shanghai. EnterpriseIQ software is now available in Simplified and Traditional Chinese, as well as English, German, Dutch, Swedish, and Spanish.

IQMS was named one of Start magazine’s “Hottest Companies” in 2004 and in 2005 was on the magazine’s list of companies to “Keep an Eye On” this year.

Strong MCAD Growth Is Seen

The worldwide mechanical computer-aided design (MCAD) and product life-cycle management (PLM) market grew to nearly $4 billion in 2004, according to research undertaken by Wohlers Associates Inc. in conjunction with Cyon Research. Wohlers and Cyon found that the top four firms in the field—Autodesk, Dassault, UGS, and PTC—had $3.871 billion in sales in 2004 as against $3.38 billion the preceding year, for an increase of 14.5%.

According to Wohlers Report 2005, net income for those four companies collectively grew by 79.7% during the period, from $271 million in 2003 to $487 million in 2004.

In terms of commercial seats, the leading MCAD product in 2004 was, according to the study, Autodesk Inventor. Following in order were CATIA, UGS NX, SolidWorks, Pro/Engineer, and Solid Edge. MCAD products not counted by the investigators included Alibre, KeyCreator, OneSpace Designer, IronCAD, thinkdesign, VX CAD/CAM, and Cobalt.

Cyon Research, which provides design, engineering, construction, and manufacturing firms with a strategic outlook regarding the software tools and processes on which those companies rely, worked closely with Wohlers, an independent business consulting firm, to determine CADsolid-modelling growth trends. This information has enabled Wohlers to forecast the expansion and acceptance of additive fabrication technology for applications such as rapid prototyping, which is the primary focus of Wohlers Report 2005. Wohlers’ worldwide study is a 256-page softcover publication that presents the state of the rapid prototyping, tooling, and manufacturing industry.

EMO Encore for Yamazaki Mazak U.K.

Anyone who missed the biggest-ever Yamazaki Mazak U.K. EMO display at this year’s machine tool exhibition in Hannover will have a second opportunity to catch up with the latest Yamazaki Mazak technology at the company’s “EMO Encore” event, which takes place at its Worcester Technology Centre November 22–25. The open house will feature 12 products from the thought-provoking EMO display.

Highlights will be the new Angulax 900 high-productivity machining centre (pictured), which introduces a new approach to multisurface machining, and the new Multiplex 8200Y multitasking turning machine that, with its combination of two spindles and three turrets, is ideally suited to single-setup applications. These post-EMO exhibits will be joined by other products from the Yamazaki Mazak portfolio, ranging from the relatively simple 2-axis lathes and 3-axis machining centres of the Nexus series to such advanced-technology machines as the Mark IV Integrex-300 ST multitasking machine equipped with the new Mazatrol Matrix CNC.

Matrix, which had its global launch at EMO 2005, is a sixth-generation control system capable of controlling up to 9 axes, including 5-axis simultaneous machining. Its calculation capability delivers high-speed, high-accuracy machining, even with submicron programme commands. Also, innovatively designed pulse encoders on each linear axis enhance surface finish quality by generating 16 million pulses per revolution.

For motor-sport enthusiasts, EMO Encore offers a not-to-be-missed opportunity to check out Kimi Raikkonen’s Team McLaren Mercedes Grand Prix car.

New West Coast Alliance Gives Methods Machine Tools a Higher Profile

Methods Machine Toolshas moved to a new office in Buena Park, California, office to better coordinate service for its customers on the US West Coast. The facility in Buena Park, 25 miles (40 km) southeast of Los Angeles, is part of a new marketing alliance between the Massachusetts-based supplier of precision machine tools and Selway Machine Tool Company, a major West Coast distributor and representative headquartered in Union City, California.

According to Method Machine Tools president Bryon Deysher, the alliance will be better for prospective buyers of machine tools as well as for longstanding Methods customers.

“Joining forces with Selway means we will have more engineers and service technicians to provide better response times, expert advice, training, and technical support,” says Deysher. “In addition to a larger sales force, this alliance also means larger inventories of machine tools and spare parts. With a larger showroom capacity, we’ll have even more machines on display.”

Notes Scott McIver, chairman of Methods, “This new arrangement makes both Methods and Selway stronger for the future.” And Bill Selway, president and CEO of Selway, says that “with the synergy of our combined operations, we are looking forward to a successful sales and support organization for southern California.”

Methods Machine Tools Inc., has been a supplier of precision machine tools and accessories for over 40 years. Methods is the exclusive North American source for Matsuura CNC machining centers, Nakamura-Tome CNC turning centers, and Fanuc RoboDrill CNC milling,drilling and tapping Centers. The Methods EDM division is the exclusive North American source for Fanuc Wire EDM machines, Exeron die sinker EDM machines, and HoleMaster high-speed hole driller EDM systems. The company provides installation, parts, service, and training through a nationwide network of dealers.

Surfware, Faro Team Up to Provide ‘Design-to-Reality’ Interface Solutions

Surfware Inc., developer of CAD/CAM systems under the SURFCAM brand, has announced an extensive collaboration with Faro Technologies, a leading provider of dimensional quality control products, to provide cutting-edge solutions in computer-aided manufacturing (CAM).

Among many new features in its latest service pack, the SURFCAM CAM software program now supports USB-enabled Faro portable measurement arms, marketed under the FaroARM name. Surfware actively pursued developing this specific enhancement to further augment what SURFCAM calls “design-to-reality” solutions.

“The SURFCAM and Faro alliance provides a seamless part digitizing to machining solution,” said Shaun Mymudes, Faro’s director of product management. “Using SURFCAM to capture dimensional data, Faro portable measurement arms provide our customers with a direct interface to a very high-end CAM program.”

The FaroARM interface for SURFCAM allows use of any Faro 6- or 7-axis portable digitizer as an auxiliary pointing device to input 3D coordinate data into an active SURFCAM session. It also allows SURFCAM users to freely intermix digitized input with all other input modes. This facilitates model creation, toolpath generation, and material removal simulation in a single environment, continuously displaying the FaroARM probe tip for graphical verification.

“Users can create, edit, generate and simulate toolpaths, then machine complex surface models all in a single setup without any file transfers,” said Don McKillop, president of CAM/CAD Technologies and the author of the FaroARM USB interface. “The SURFCAM FaroARM interface is uniquely suited for reverse engineering of complex 3D objects.”

This interface now supports both serial and USB connectivity, enabling the system to work with legacy and current Faro equipment. It includes a variety of convenient coordinate alignment techniques, probe calibration, probe changing within a session, system diagnostics, and a series of convenient digitizing modes. Digitizing modes include discrete point input, lock-plane input, streaming-coordinate mode input, and project-onto-plane input.

“We are proud to work with Faro Technologies to provide state-of-the-art ‘design-to-reality’ solutions,” commented Joe McChesney, product manager at Surfware. “We will strive to continue offering enhancements to SURFCAM that deliver the latest cutting-edge technologies to our customers.”

Granta Design Software to Include Portion of Moldflow Database

The recent 2003 International Moldflow User Conference was the occasion for Moldflow Corp. to announce a strategic partnership with Granta Design Ltd., known for its expertise in materials information technology. According to the agreement, portions of Moldflow’s proprietary plastics material database will be included in Granta’s CES4 Optimal Polymer Selector (OPS) product. OPS provides a systematic method for the selection of the most appropriate plastics material for a given application.

Granta customers will now be able to filter materials based on the availability of Moldflow material data, an important capability for customers using Moldflow analysis products in their product development processes.

“Granta customers will now have the ability to quickly eliminate materials that have not been characterized for use with Moldflow software tools in the earliest stages of determining material candidates for a given application,” says Peter Rucinski, Moldflow’s director of product marketing. “This further underscores the importance of having the necessary data to use Moldflow software products to perform analyses in those early stages of product development, when the cost of change is minimal yet the impact is greatest.”

Pathtrace Sees Growth and Potential in East Asian Sales

Two new Pathtrace Engineering Systems sales operations in China and Japan are predicted to contribute more than £1 million (about $1.6 million) in sales of the company’s EdgeCAM off-line programming software this year. Pathtrace Engineering Systems is a division of Pathtrace plc.

According to managing director Brian Steatham: “With the massive global investment in manufacturing in China by existing users of EdgeCAM, the market potential even without adding new customers is enormous. When we add our business potential from our operations in Japan where we are scoring high levels of success due to our solids-based, high level programming interface to any CAD system, the future looks very positive.”

Pathtrace operations in China are largely focusing on mold and die applications, where the solid and surface machining capability of EdgeCAM is drawing considerable attention. EdgeCAM has already been translated into Chinese and six people have been recruited to focus sales initially in the Beijing area.

The Japanese operation, based in Nagoya, is described as a center of excellence for Asia and is focusing on production machining of more complex components.

Both sites are currently partnerships but will become fully owned by Pathtrace later this year.