The process of manufacturing plastic components varies according to the type of part being made. Most parts of this sort are made by a technique known as plastic injection molding. Quality production depends on understanding this process and how it can be adjusted to create components which possess the desired features for their application.
Some examples of products made using the molding technique include electronics, toys, bottles, and automotive parts. Manufacturers appreciate the high precision, low labor expenses, efficient use of materials, versatility in the plastics which can be used, and the ability to produce a high volume of parts at once.
Plastic polymers such as elastomers, thermosets, and thermoplastics are the materials used for injection molding. A vast assortment of polymer blends are available for manufacturers to choose from; each with its own unique properties. Selection of the right polymer is usually determined by the strength and intended final use for the finished product.
The equipment involved in this process includes a press, or injection molding machine, and molds. A press consists of a hopper, plunger, and heating unit. These machines are rated by tonnage, which refers to the tons of clamping force exerted to keep the molds closed when in use. Molds can be made from a variety of metals, and consist of hollow shells in the shape of components being made.
The process begins when solid plastic is fed into the hopper of the press and moved along by the action of the plunger to the heating unit where it will be melted. The liquid is then injected through a nozzle into the mold, where the setting takes place under a steady pressure and temperature before the pieces are cooled and ejected. Designing molds in a way which reduces stress on the parts being made is very important when it comes to minimizing product defects.
The gates are the openings on the mold through which the molten polymers are injected into the cavity. These gates can differ in size, location, and design. In general, larger parts require larger gates. Another point to consider, is the thickness of the walls of the molded object; thinner walls will help reduce the length of the cooling cycle and also save materials.
If something other than a smooth surface is desired for a molded object, a process known as texturing is implemented. Patterns are added to the surface of the part to give it a particular appearance. Besides serving an aesthetic purpose, this technique can also be useful in a practical sense for disguising minor flaws and to minimize the effects of friction over time.
Some examples of products made using the molding technique include electronics, toys, bottles, and automotive parts. Manufacturers appreciate the high precision, low labor expenses, efficient use of materials, versatility in the plastics which can be used, and the ability to produce a high volume of parts at once.
Plastic polymers such as elastomers, thermosets, and thermoplastics are the materials used for injection molding. A vast assortment of polymer blends are available for manufacturers to choose from; each with its own unique properties. Selection of the right polymer is usually determined by the strength and intended final use for the finished product.
The equipment involved in this process includes a press, or injection molding machine, and molds. A press consists of a hopper, plunger, and heating unit. These machines are rated by tonnage, which refers to the tons of clamping force exerted to keep the molds closed when in use. Molds can be made from a variety of metals, and consist of hollow shells in the shape of components being made.
The process begins when solid plastic is fed into the hopper of the press and moved along by the action of the plunger to the heating unit where it will be melted. The liquid is then injected through a nozzle into the mold, where the setting takes place under a steady pressure and temperature before the pieces are cooled and ejected. Designing molds in a way which reduces stress on the parts being made is very important when it comes to minimizing product defects.
The gates are the openings on the mold through which the molten polymers are injected into the cavity. These gates can differ in size, location, and design. In general, larger parts require larger gates. Another point to consider, is the thickness of the walls of the molded object; thinner walls will help reduce the length of the cooling cycle and also save materials.
If something other than a smooth surface is desired for a molded object, a process known as texturing is implemented. Patterns are added to the surface of the part to give it a particular appearance. Besides serving an aesthetic purpose, this technique can also be useful in a practical sense for disguising minor flaws and to minimize the effects of friction over time.
About the Author:
Genevive B. Mata has taught plastics molding techniques for over 15 years. He specializes in injection molding and thermoforming. If you are interested in learning more about plastic injection molding services then he recommends you visit his friends at PTM: Custom Plastics Injection Molding Company.
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