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Archive for the ‘Short Run Injection Molding’ Category

Liquid injection molding is commonly known as the technique for producing a wide range of product from different materials. Two of the most commonly used materials are plastic and liquid silicone. Both of them have good flexibility which is beneficial for the ease of the production. To industrial setting, this process is very beneficial since it allows them to create a lot of identical parts in a short time.

The plastic which is used for this process is firstly melted before it is molded. The melted plastic can be easily formed into the desired shape. On the other hand, if the silicone is used, it will be cured through chemical process by combining the base of the rubber with the catalyst. This process can be done outside the mold before or during the injecting process.

This silicone or plastic is injected to the closed and locked mold by using the plunger syringes. In this mold, the plastic will be cooled. On the other hand, the silicone will be cured when the process of chemical runs the course. In addition, if the silicone is not previously catalyzed, it will be added using the rubber base as well as the catalyst. Simply inject the catalyst and rubber base to the mold using two separate plungers. If all the parts have been cooled and cured, they will be ejected out of the mold.

To perform the process of liquid injection molding, you will need special machinery. That machinery used is very complex with some different standard parts including supply drum which is to handle the raw materials such as silicone, plastic, and pigment till they are ready to be employed. Another part is metering units which are to pump the some different liquid components into the mixer in the premeasured proportions so that all the raw materials can blend into one. Another part is injector which is to force the casting material into the mold by using pressurized force.

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All of this material started out generally as plastic pellets. The pellets are feed into one of the huge molding machines, these machines often weigh around twenty-five tons. The machine heats the plastic till it is liquid. This liquid is then forced thru injectors into molds.

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These molds can be made to almost any shape or size. To put it simply, injection molding is the process of causing liquified plastic in to a mold hole. Once the plastic has cooled, the part can be ejected. It is useful when the parts are too complicated or cost prohibitive to machine. With this process, many parts can be made at the same time, out of the same mold.

The method has usually 6 steps :

1. Clamping : the machine has 3 parts. The mold, the clamp and the injection unit. The clamping unit holds the mold at a certain pressure, this ensure uniformity in the units that are outputted. Molds are usually made of two parts.

2. Injection Unit : this is where the plastic pellets are loaded into a hopper at the top of the injection unit. The pellets are fed into the main cylinder ; this is where they are heated until they are liquefied. Within the injection unit there is a screw which turns and mixes the plastic. Once this liquid plastic has reached the ideal for this product the injection process starts. The plastic is forced thru a sprue and the pressure and speed are under the control of the screw or sometimes a ram depending on the sort of machine.

3. Dwelling : this is a pause in the process while some pressure is applied to ensure all the mold cavities have been completely filled. This is vital within the process as it will end up in scrap of units if the mold isn’t filled in the right way.

4. Cooling : this part of the process lets the mold cool for the necessary period. If it is done too quickly the units can stick or become misshapen once out of the machine.

5. Mold Opens : The clamping unit is opened to separate the mold. Molds are used over and over again ; they are often the most vital single part in the whole process. The tooling of mold can be extremely costly.

6. Ejection : the finished product is ejected from the injection mold machine. Frequently the finished product will continue on a production line or be stacked to go to a production line as parts for larger products, e.g. Car wheel.

The products that use injection molding are used every day by all of us. Many vehicles wouldn’t be so affordable if it wasn’t for injection molding, however there are some downsides to the method. The machinery is very expensive and involves a high capital investment, design of parts must bear in mind the production process, and the process isn’t economically for short runs of products.

However the downside are out-weighed by the larger benefits, The speed at which parts can be made, low labor costs, minimal material waste, and finished parts frequently need no more finishing.

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Now you can apply color to one – or a million and one – plastic parts with the patented AURA® color infusion technology process. This post-molding coloring technology offers several benefits, especially for applications that need to be produced in a number of colors. Since color is infused into parts made from clear, translucent or opaque resins, you can reduce inventory of pre-colored resins or colored parts. The AURA color infusion technology allows true coloration on-demand, adding speed and flexibility to production. Customers control the color process in-house and can make frequent color changes easily. AURA color infusion technology is ideal for short-run, made-to-order, customized products produced by injection molding or extrusion.
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