The impact of injection molding on the world is much lager than than many people think.
Since its invention in the late 18 th century, the molding technology (along with the plastics industry) has turned into a multi billion dollar industry. Injection molding manufactures around 32% of plastics of the world, by weight.
Because of this process, the costs of a lot of consumer and industrial components, such as encasing, knobs, laptop housings, toys, car bumpers are made cheap.
Components and specifications of the molding machine:
A typical injection molding machine is made up of the following components: the injection system, hydraulic system, mold system, clamping system and control system. For thermoplastics, the injection molding machine turns pelleted or granular raw plastics into final molded parts using of the following: melt, inject pack and cool cycle.
Clamping tonnage and shot size are usually used to quickly identify the size of the injection molding machine for thermoplastics.
Other parameters are as follows: injection rate, injection pressure, screw design, thickness of mold and the distance between tie bars.
Functions of the machine
Injection molding machines are classified into three categories namely based on machine function: general purpose machines, precision tight-tolerance machines and high-speed, thin-wall machines.
Injection moldings machines also operate using auxiliary equipment, the most important of which include resin dryers, materials-handling equipment, granulators, part-removal robots, mold-temperature controllers and chillers and part-handling equipment.
Expert injection molding companies
Some companies are experts in plastic molding injections. They can manufacture plastics of difficult or high volume parts from a lot of engineering resins.
They also offer plastic injection molding and tooling services. These companies typically have a design group that can assist you with plastic parts and mold designs you require. They have factory controls that can inspect and monitor the process of the parts along with the latest in inspection equipment. This enables them to match the closest tolerance and provide quality that is consistent.
Recently we have seen many innovations in the injection mold machines, but the tooling cavity and cores) have been not much changed in the last decennia, accept that now 3d printing is used for cavity and cores. ( only for extreme low volumes ) . Luckily now sensors can be put in the molds to avoid warpage and other problems due to temperature variations. These sensors measure the melt surface and melt mid-plane temperature in order to influence local cooling. In that case the mold operator will have a mold trial within a very short time , superior parts and of-course stable production with minimal residual stress.
Another helping device to run you batch smoothly is the use of hot-runners in the process.. Currently Hot runners are replacing cold runners at a large scale. Because of the inefficiency and higher cost of production associated with cold runner and the contrary benefits of the hot runners, the use of this system in the injection molding process has increased.
Of course this technology being molded by best company such as our company..
to incorporate these technologies one has to execute a good benchmarking of current best practices of the critical components , and management has to ask hiself "How much will it cost to engage the latest technologies to achieve that benchmark?" and "Do the benefits support the cost of implementation of these technologies?"
Of course with injection molding being a market for which there are a number of machine manufacturers seeking sales, the competitive edge and potential market size may justify the investment in R&D or commercial development if the technology could be introduced to a range of machinery. But if the technology was aimed at a specific market (i.e. machinery greater than 5,000 tone clamp pressure) then this may be a deal breaker.
The next stage would be to convince the customers that the benefits to their business in adopting this new technology justifies the investment, as they would also need to look at their targeted market base.
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