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Plastic Injection Molding and Its Advantages

The identification of the product plays an extremely important role in the communication of the position and brand of a product in the market. Plastic identification plates can transmit messages, marks, classifications, descriptions, diagrams, warnings, instructions and many other types of product information.

Plastic injection molded nameplates help identify your products and help them stand out from the crowd. Before going any further, let's take a quick look at the plastic injection molding process.

The process of plastic injection molding

The process of plastic injection molding is not complicated. The molding processes of this type involving metals go back many years, and the basic principles have not changed, only the methods and materials.

Of course, you have seen what the finished product looks like. You have seen them more times than you can consider. You have seen them as emblems of automobiles, appliances and industrials, custom plastic plates, plates of recreational products, points of purchase, plates and signs. They fill the world around you, but do you know how they are made?

The process begins with a plastic tablet made of an organic and inorganic polymer compound, as well as additives to aid in the fusion process. This small pellet is thrown into a hopper with thousands of other pellets. This starts the trip from pellet to product. The next step is to prepare the plastic.

The pellets are released into the threads of a giant rotating screw. As the pellets travel, they are heated to fusion temperatures, around 400 degrees Fahrenheit. Of course, the higher the quality of the plastic, the higher the temperature necessary to melt it. The pellets are wound along the screw because the process also requires friction and strength. The screw provides both as the pellets roll along their surface and collide with each other.

Now that the three requirements, friction, force and heat are met, the granules begin to liquefy and the next filling step begins. The screw continues to guide the liquid plastic along its threads to a valve. Under high pressure, the valve forces the plastic into a custom designed mold, made of heat-resistant metals, until each cavity is filled. Once this is achieved, the mold enters the maintenance phase. The filling and maintenance phases are crucial steps in the plastic injection molding process. Its execution will determine the quality of the finished product. The metals that we use for the mold ensure that the last piece manufactured has the same qualities as the first.

The next step

The pressure on the mold is maintained while the molten plastic is cooled to a solid state. This stage could take a few minutes as the mold absorbs the heat of the melted plastic and, in turn, cools with the refrigerant that surrounds it. While the piece cools, the screw returns to its original position and collects more pellets from the hopper. The product is expelled from the mold and passes to secondary processes, such as decoration, sub-assembly or shipping. The mold is closed and the process begins again.

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[asabenito-blog]

Injection Molding-How Plastic is Molded

Plastic has literally become the cornerstone of our society. We do so many plastic things that it's hard to imagine what our lives would be like if it had never been invented. With so many of our everyday products made of plastic, it is easy to understand why plastic injection molding is such a big industry.

Approximately 30% of all plastic products are produced by an injection molding process. Of this 30%, a large quantity of these products is produced through the use of custom injection molding technology. Six steps are involved in the injection molding process, after the prototype has been made and approved.

The first step to the injection molding process is the mold clamping. This clamping unit is one of the three standard parts of the injection machine. They are the mold, the closing unit and the injection unit. The clamp is what actually holds the mold while injecting the molten plastic, the mold is kept under pressure while the injected plastic is cooling.

The following is the actual injection of the melted plastic. Plastic generally begins this process as pellets that are placed in a large hopper. The granules are then fed to a cylinder; here they are heated until they become molten plastic that is easily introduced into the mold. The plastic remains in the mold, where it is held under pressure until it cools.

The next steps consist of the housing phase, which basically consists of making sure that all the mold cavities are filled with melted plastic. After the housing phase, the cooling process begins and continues until the plastic solidifies inside the form. Finally, the mold is opened and the newly formed piece of plastic is ejected from its mold. The piece is cleaned of any extra plastic from the mold.

As with any process, there are advantages and disadvantages associated with plastic injection molding. The advantages outweigh the disadvantages for most companies; they include the possibility of maintaining high levels of production, being able to replicate a high level of tolerance in the products that are produced, and lower labor costs, since most of the work is done by machine. Plastic injection molding also has the added benefit of lower scrap costs because the mold is manufactured with such precision.

However, the disadvantages can be a decisive factor for smaller companies that want to use plastic injection molding as a way to produce parts. These disadvantages are that the necessary equipment is expensive, therefore, increase operating costs.

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