Month: October 2019

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.