What are the Advantages and Disadvantages of Plastic ...
Aug. 06, 2024
What are the Advantages and Disadvantages of Plastic ...
What are the Advantages and Disadvantages of Plastic Injection Molding?
- Plastic Injection Molding |
- Aug 3,
You may already have a bit of knowledge about plastic injection molding if you have landed on our blog today. Plastic injection molding is among the most commonly used processes for manufacturing, creating a huge number and a massive variety of pieces and parts.
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Overview of Plastic Injection Molding
Injection molding is commonly known as injection molding, a manufacturing process utilized in plastic parts mass fabrication. It consists of injection of the molten plastic material into the mold, where it will solidify and cool to its final form. It is the best mechanical assembly for the higher volumes of plastic products serving various individuals and industries.
The mold is customized during the design & development stage giving the proper shape to the part. It can also create several parts that are dimensionally consistent and identical, even on parts having complex designs allowing lower tolerance on dimensions.
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Advantages of Plastic Injection Molding
#1. Precision
In terms of manufacturing intricate parts, plastic injection molding is perfect. Molding allows you to incorporate several features at smaller tolerances than other techniques. The mechanical assembly of this machine has several smaller parts.
#2. High Repeatability
The identical products are made repeatedly once the molding tool is created. The mold tool has longer life as it is made decently as long as it is treated appropriately through molding the machine setters.
#3. Low Cost Per Part
The cost per part is quite low, while there is an initial high investment for the tool for plastic injection molding. The other processing techniques would involve several operations like polishing; injection molding can be done all together at once. The CNC machine will cost hundreds of pounds for each part. Injection molding is the best way to go if you are searching for complete production.
#4. Fast
The cycle time is as low as 10 seconds. Combining this with a multi-impression injection molding tool can allow you loads of products quickly. Some parts take a bit longer since it is a specialist material with several features that need molding in a precise way.
#5. Material Choice
There are a massive amount of materials that are available for plastic injection molding. There is a range of more common materials with things like antistatic plastic, chemical-resistant plastics, thermoplastic rubber, and more. You even have endless color choices, too, with masterbatch coloring or color compounding.
#6. Special Surface Finishes, Engraving, and Printing
The injection molding tool is made out of special finishes that show on the molding along with the range of colors. You can get all types of finishes like the leather look, sparked, higher shine, l and more. You can even have logos along with other texts engraved into the mold. Lastly, you can have your moldings printed as a range of inks are made available and printed well onto the plastic.
Also Read- Importance of Good Plastic Molding Dies
#7. Little Plastic Waste
The part repeatability is quite high for injection molding even the runners and sprues are there, with the leftover bits of plastics being created out of tunnels through which the plastic material reaches the actual mold. And the reground and material is reused.
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Disadvantages of Plastic Injection Molding
#1. High Initial Cost
Several rounds of molding and designing are required before the production, or the go-ahead is given. After which injection molding tool is required for making the moldings, including designing and manufacturing.
The mold tool is the essential piece of work, cutting down on the manpower and material cost, along with several machining hours for making and representing the largest cost one gets in injection molding. Surely, once everything is done, the part cost is quite low, and repeatability is very high.
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#2. Initial Lead Time
The final part can take months of design, testing, and manufacturing of tools from the production concept. If you know what you wish, you can have the finished moldings within 6 weeks. Once the tool exists, it takes quite less time to operate the moldings, especially while you have a multi-impression mold tool, as you have already noted under the benefits.
#3. Large Part Size Limitations
There are massive machines that are required for making plastic injection moldings. The larger parts require a massive mold tool that becomes quite expensive in manufacturing. The process involving plastic fabrication is the best choice as it depends on the type of product that you needs.
#4. Careful Design Needed
The plastic moldings require careful designing under mechanical assembly to avoid the tooling issues involving the undercuts, locked-in features, and not sufficient draft. The temperature and material will be taken into account in the wall design. Else, the mold will not be filled fully. The placement of cooling lines and ejectors needs consideration to ensure that the product appears good.
So, these are a few aspects you must know about plastic injection molding.
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Advantages and disadvantages of plastic injection moulding
Thermoplastic Injection Moulding is a very commonly used process to manufacture identical parts that are required to be produced in large volumes. The Plastic Injection moulding process is injecting molten material into a closed mould. By using a variety of materials for a properly designed part and a mould to facilitate the moulding process, we can produce the required parts consistently and economically.
To understand the process of Plastic Injection Moulding, the granules of plastic material are loaded onto the machine using a hopper loader into the hopper, which is one of the simplest conveying systems.
The plastic material then passes through a heated barrel (under controlled temperature) and is injected under high pressure through a runner system into the cavity of the mould. The cavity and core define the shape of the part that is to be moulded. Once the injection process is completed to fill the cavity, the part needs to be cooled before the mould opens and the part is ejected and removed from the mould. This process repeats, allowing each cycle to produce an identical part. The Plastic Injection Moulds are manufactured using Special tool steels and specialist equipment and tools.
Advantages of Injection Moulding
Fast production &#; Plastic Injection moulding process can produce more number of parts per hour, depending on how many cavities/impressions there are in the moulding tool. When a good moulding tool design is manufactured with an effective filing system, cooling circuit and ejection system, we can produce consistently good parts with reduced cycle time.
Significant strength enhancement -The plastic injection process offers a unique option within applications where parts need to be strong or durable. In plastic injection moulding, it is possible to use fillers with the moulding raw material which reduces the plastic materials density, while also adding greater strength to the moulded part.
Material, Texture and Colour Flexibility &#; the material and colour can be changed depending on the customers&#; requirements. The texture and finish required can be produced on the part.
Reduced finishing operations &#; There is often very little post-production work required on these injection moulded parts, they usually have a good finished look upon ejection.
Ability to use multiple materials &#; Multiple plastic materials can be used simultaneously during the injection moulding process &#; over moulding, and also metal inserts ( usually for threaded applications) can be used as inserts to be kept in position in the mould before the moulding cycle starts. After the injection moulding process is completed, the moulded part along with the inserts is ejected from the mould.
Low Labour Costs &#; a well-designed automatic plastic injection mould can run without any interference by human labour, which means the required parts can be ready with little or no labour for production.
Design Flexibility &#; when you are able to design a part considering the design restrictions, we can integrate other parts of an assembly into a single plastic injection to reduce the cost and production time for these parts.
Scrap &#; A well-designed mould can produce parts without runners by using hot runner systems. Commonly most moulds produce runners for every part moulded. A majority of the moulders recycle these runners by grinding for reuse.
Disadvantages of Injection Moulding
High initial costs &#; the main disadvantage of plastic injection moulding is the plastic injection moulding tool, plastic injection moulding machine and its auxiliary equipment which are very high.
Lead time &#; from product conception to the final part, it can take months of design, reviews, testing and tool manufacturing. Once the tooling is done, as mentioned under the advantages, it takes very little time to produce the required parts, especially when you have a multi-cavity / impression moulding tool.
Not cost-effective &#; producing parts required in low volume is less cost-effective.
Design restrictions &#; unless an experienced design team works on the part required along with the mould manufacturer and the raw material suppliers, there may be few restrictions in the part for Plastic Injection Moulding.
Contact us to discuss your requirements of automotive interior molds. Our experienced sales team can help you identify the options that best suit your needs.
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