The injection molding process consists of specific production cycles that make use of different injection molding components to receive adequate products. The process of injection molding capable of producing products for a variety of industries, including specialized injection-molded healthcare products and other bioceramic components for the medical industry.
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But, in order for an injection molding company to be able to manufacture different parts and products per client&#;s exact specifications, it is necessary to know the details of the process itself, including its cycles. That is why we&#;re going to take a closer look at the four different production cycles of the injection molding process.
The entire process of injection molding for a single set of components can be very short and can last as little as two seconds. On the other hand, larger and more complex components can take as long as two minutes to complete.
Regardless of the time necessary to complete an injection molding process, it is important to be familiar with the four main stages in the cycle &#; clamping, injection, cooling, and ejection. Let&#;s see what they entail.
Before injection of the mold with adequate material, the halves of the mold have to be closed. The clamping unit closes the halves of the mold before the machine injects the compound into it.
Upon closing the two parts of the mold together, the clamping unit continues to apply the necessary amount of force in order to keep the mold closed as it is being filled with the material. The larger the injection molding machine, the longer it takes to adequately close and clamp the mold.
During the injection portion of the molding process, the hopper injects the compound into the mold. The injection time varies depending on the type and size of the mold, as well as the compound injected into it.
The pressure of injection ranges from 35 MPa to as much as 140MPa. Both the pressure and the rate of injection are controlled by the injection molding machine&#;s hydraulic system.
This is an important part of injection molding, as it cools the material inside the mold, allowing it to achieve the desired shape and characteristics, bringing it closer to the finished product. The part being molded can shrink during this portion of the process. The mold can be opened only once the estimated cooling time is reached.
This is the last stage of the injection molding process and it is performed with help from the ejection system. The mold opens and the ejection system pushes the finished product out. It is necessary to apply force to the product as it usually sticks to the mold. Upon ejection, mold can be clamped again to continue the process of injection molding.
It is important to select adequate and high-quality materials for the injection molding of a specific component, as well as to pay great attention to the design of the entire process. However, it is also vital to be familiar with the different cycles in the process of injection molding in order to learn how to get the most out of the procedure. That is where experts from Wunder Mold excel. They have the necessary knowledge of every single part of the injection molding process and ample experience in manufacturing adequate parts and components.
Wunder Mold has more than twenty-five years of experience making different components through plastic and ceramic injection molding. Our mission is to provide our clients with a wide selection of components that fit their exact requirements. We take the time to listen to the needs of our clients, we pay attention to their input, and give them an end-product they will be able to use to their full advantage. Reach out to us by calling (707) 448- or by sending an to .
Boss
Refers to the round protrusions on plastic parts and molds (#2 in Figure 1 below)
Cavity
Refers to the upper half of the injection mold usually the show surface of the finished product but is mainly concave
Core
Refers to the side of the tool where the plastic part is injected from; also known as the bottom half of the tool
Core Outs
Refers to the portion of a part that is gutted out in order to achieve uniform wall thickness. This portion of the part has no end use function other than lightening the part and reducing warp
Draft
Refers to portion of injection molding part that has some taper to make it easier to remove from the mold. Generally all plastic components should be designed with draft where possible
Gate
Refers to where the plastic enters into the cavity of the mold. The two types of gates are as follows:
1. Automatically Trimmed Gates: Gates that incorporate features in the tool to break or shear the gate as the molding tool is opened to eject the part
2. Manually Trimmed Gates: Gates that require an operator to separate parts from runners during a secondary operation
Gibbs
Area of the custom injection mold that holds the slide down so the cam can actuate it
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Hand Load
Aluminum or steel feature in a mold used to create undercuts in molded parts. They are manually removed from the mold during the part ejection process.
Heel
Refers to the portion of an automatic custom injection mold that keeps the slide in the forward position when the molding machine is closed on the mold
Horn Pin
Pin used to actuate the slide on an automatic injection mold
Line of Draw
The direction in which the two custom injection mold halves will separate from the plastic part allowing it to be ejected without any obstructions from metal creating undercuts
Ribs
Refers to thin bladed features on a part that are used for strengthening wall sections and bosses. Also, used to minimize warp (#3 in Figure 1 below)
Runner
A channel cut into custom injection molds, in which plastic travels from the injection molding machine, through the sprue, through the runner and then through the gate ultimately filling the part
Shear
Refers to when plastic enters into the mold and the melt is maintained by friction produced by speed and pressure. Too much shear can cause the plastic material to burn, too little can cause the material to freeze off causing short shot
Short Shot
The result of a plastic part not filling completely, including some or all of the details
Shrink Rate
Refers to how much the plastic material will shrink after cooled. This % of shrink is added to the part before the mold is designed. Every plastic material has its own shrink rate ranging from .001 per inch to as much as .060 per inch. Although most fall in between .004" and .021"
Side Action
Term used for slides and/or hand pulls used in the injection mold build process
Sink Marks
Refers to areas of the molded part where it seems to be sunk in, due to un-uniformed wall sections, thick wall sections and rib/boss to thickness ratios being off
Slide
Area of the custom plastic injection molds that is used for creating undercuts. Required for automatic injection molds
Sprue
Channel that links the injection molding machine nozzle to the runner
Steel Safe
Refers to the amount of metal left on the mold in order to tweak in a dimension. For example, if you have an inside diameter that is supposed to be .500 you may leave the mold at .505 in case you get excessive shrink
Thin Wall Molding
The molding of plastic parts with wall thicknesses .005" to .060" thick
Undercuts
Refers to the portion of the designed component where a slide or hand pull is required to create holes, windows or clips that are not in the line of draw (#1 in Figure 1 below)
Vestige
Material protruding from the gate area after gate runner has been removed from the injection molded part. This vestige is usually trimmed by the molding machine operator
Wall Thickness
Refers to how thick the cross section of the plastic part is
Warp
Refers to area of a injection molded part that distorts during cooling or molding, causing undesired results in the finished product. Usually caused by un-uniform wall sections
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