5 Major Advantages to Using Plastic Injection Molding for the Manufacturing of Parts
Plastic injection molding is extremely versatile method of producing parts and products. It is one of the preferred methods for manufacturing parts because it has multiple advantages over other methods of plastic molding. Not only is plastic injection molding simpler and more reliable, it is also extremely efficient. You should have no doubts about using this method to manufacture parts.
Here are 5 major advantages of using injection molding for manufacturing plastic parts and components.
1. Detailed Features and Complex Geometry
The injection molds are subjected to extremely high pressure. As a result the plastic within the molds is pressed harder against the mold compared to any other molding process. Due to this excessively high pressure, it is possible to add a large amount of details into the design of the part.
Furthermore, due to high pressure during the molding process, complex and intricate shapes can easily be designed and manufactured which otherwise would have been too complicated and expensive to manufacture.
2. High Efficiency
Once the injection molds have been designed to the customer’s specifications and the presses pre-programmed, the actual molding process is very quick compared to other methods of molding. Plastic injection molding process hardly takes times and this allows more parts to be manufactured from a single mold. The high production output rate makes plastic injection molding more cost effective and efficient. Typically, hot-runner ejection mold systems produce parts with more consistent quality and do so with faster cycle times, but it’s not as easy to change colors nor can hot runners accommodate some heat-sensitive polymers. Learn more about the key differences between hot-runner and cold-runner systems.
3. Enhanced Strength
In plastic injection molding, it is possible to use fillers in the injection molds. These filler reduce the density of the plastic while it being molded and also help in adding greater strength to the part after it has been molded. In fields where parts need to be strong and durable, plastic injection has an option that other molding processes do not offer.
4. Ability to Use Multiple Plastic Types Simultaneously
One of the major advantages of using plastic injection molding for manufacturing parts is the ability to use different types of plastic simultaneously. This can be done with the help of co-injection molding, which takes away the worry about using a specific type of plastic.
5. Automation to Save Manufacturing Costs
Plastic injection molding is an automated process. A majority of the injection molding process is performed by machines and robotics which a sole operator can control and manage. Automation helps to reduce manufacturing costs, as the overheads are significantly reduced. Furthermore, with reduced labor force the overall cost of manufacturing the parts is reduced and this cost saving can easily be passed on to the customer.
Furthermore, automation allows for making precise and accurate injection molds. Computer aided design (CAD) and computer aided manufacturing (CAM) allow close tolerances during the making of the molds.
The Bottom Line
Using injection molding also ensures the parts manufactured hardly require any work after the production. This is because the parts have more or less a finished appearance after they are ejected from the injection molds.
Today, plastic injection molding is an environment-friendly process. The scrap plastic generated during the production process is reground and re-used. Hence, the process generates very little waste.
In this article from Plastics Today, a DuPont sponsored survey indicated that “lightweighting and use of lightweight structural materials will be the key enabler in realizing 2017-2025 CAFE (Corporate Average Fuel Economy) standards.”
“In terms of lightweighting strategies, while use of aluminum topped the leader board with 27 percent of respondents saying they were most heavily relying on the metal to achieve CAFE standards, multi-material solutions came in second (16 percent), with engineering plastics third (13 percent).” Manufacturing companies, especially in the auto industry are racing to create safe, affordable, and fuel efficient prototypes. And plastic is helping to reduce vehicle weight.
“This is a marathon – not a sprint. Clear strategies need to be set, checkpoints need to be established and the most effective tool we have in this race is collaboration.”
Plastic injection molding pressures are classified based on the clamping pressure that the molding presses exert. This is the reason why it’s important to check the size of the press, which is often referred to as the tonnage. The clamping pressure exerted by the press can range anywhere from 5 tons to more than 4,000 tons. (more…)
“Design teams are always trying to come up with something better—better shapes and designs, better performance, better materials, and lower costs. They are constantly seeking something that will give them an edge over the competition.”
But being creative is harder when you’re dealing with metals. Regardless of how lean you go, cost is still the greatest factor. That’s why changing from metal components to plastic ones could save you up to 50 percent in operational costs without compromising function or quality. It caneven improve design choices and options, giving the design teams the creative license they need.
In this great article from Kaysun Corporation, they outline how injection-molded plastic can replace metal in many instances and what advantages plastic has over other materials.
Why should you choose a hot-runner mold system over a cold-runner mold system (or vice versa)? Each type of molding system has unique features that help determine exactly which one is best for you.
Cold-Runner Mold Systems
Called a cold-runner mold system because the runners are the same temperature as the molds, there are two types of cold-runner systems: a three-plate system and a two-plate system.
Three-plate systems allow the part to be ejected from the runner without an ejection system, but are a little more complicated than a two-plate system, which does require an ejection system to remove the part and the runner from the mold. Two-plate systems can handle most molds, however a three-plate system is friendlier when it comes to complex designs.
In a cold-runner mold system, the runner has to be larger than the part. Otherwise, you run the risk of underfilling the mold. One big advantage over a hot-runner system is the ability to use more types of polymers without concern for heat sensitivity.
Cold runners are less expensive than hot runners and are easily maintained as well, but they can create waste unless you can recycle or melt down the extra material.
There are two types of hot-runner mold systems, both of which use two plates heated by a manifold system. Externally heated molds allow you to use more heat-sensitive polymers while internally heated molds generate better flow control. Depending on your materials and applications, you may prefer (or need) one type over the other.
Hot runners are more expensive than cold runners (in initial investment and maintenance), but they can handle higher volumes and larger parts and also don’t generate any waste. In some cases, the lack of waste balances with the higher maintenance cost to actually be about the same net cost as a cold-runner system.
Overall, hot-runner molds produce parts with more consistent quality and do so with faster cycle times, but it’s not as easy to change colors nor can hot runners accommodate some heat-sensitive polymers.
Pros and Cons of Hot Runner System
Pros
Fast cycle time
Consistent quality
Very little waste
Ideal for larger parts and higher volumes
Cons
Expensive to purchase and maintain
Not ideal for some heat-sensitive polymers
Difficult to make color changes
Which System is Right for You?
Depending on exactly what you’re doing with your molds—materials, applications, size, volume, etc.—you may have a clear answer as to the best mold system or it may be more complicated. For instance, if you’re only working with heat-sensitive polymers, a cold-runner mold system is probably your best choice. If you’re producing large volumes and need faster cycle times, you’re probably looking for a hot-runner mold system.
However, those aren’t definite answers and shouldn’t be taken as such. You need to consider every facet of what you’re doing to determine the best system for you. Feel free to contact us if you’d like to talk about which type of mold system is your best option.
When you’re buying molded parts made from different types of plastics, it’s crucial you know about some of parts defects that can lower the quality of the molded plastic parts. If you know the sources of the defects and flaws they can cause, you can work in conjunction with your plastic injection molding company to maintain the highest standard of quality during production. (more…)
This website uses cookies so that we can provide you with the best user experience possible. Cookie information is stored in your browser and performs functions such as recognising you when you return to our website and helping our team to understand which sections of the website you find most interesting and useful.
Strictly Necessary Cookies
Strictly Necessary Cookie should be enabled at all times so that we can save your preferences for cookie settings.
If you disable this cookie, we will not be able to save your preferences. This means that every time you visit this website you will need to enable or disable cookies again.
