3D Blow Molding
3D blow molding technology is very advantageous because its advantages of seamless welding and uniform wall thickness can maintain the overall quality and aesthetic performance of the product.
3D Blow Molding
- Off-axis Extrusion Blow Molding
- Robot or Manipulator Holding the Parison
- Sequential Opening and Closing Mold with Vacuum Assist
3D Blow Molding Capabilities
3D Blow Molding produces complex, integrated designs with minimal waste, makes 3D blow molding an attractive option for various industries seeking to optimize part performance, reduce costs, and improve sustainability.
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US
Metric
PP
27.6in. x 27.6 in. x 15.8 in.
700mm x 700mm x400mm
HDPE
27.6in. x 27.6 in. x 15.8 in.
700mm x 700mm x400mm
PVC
27.6in. x 27.6 in. x 15.8 in.
700mm x 700mm x400mm
PC
27.6in. x 27.6 in. x 15.8 in.
700mm x 700mm x400mm
*3D blow molding is ideal for manufacturing complex curved pipes, ducts, and other hollow components without parting lines or excessive flash.
3D Blow Molding Material
Materials with higher processing temperatures, like nylons and engineering plastics, are often used for automotive engine pipes and technical parts that require higher temperature and chemical resistance.
Material
- PP
- HDPE
- PVC
- PC
The Advantage & Disadvantage of 3D Blow Molding
3D blow molding requires specialized equipment, tooling, and expertise, making it more suitable for applications where the benefits outweigh the additional complexity and costs involved.
Advantage
Disadvantage
Cost-effective Production
Limited Material Options
Design Flexibility
Limited Wall Thickness
Consistent Quality
Limited Part Size
Lightweight
Production Time
Application of 3D Blow Molding
3D blow molding has several key applications across various industries: automotive industry, air ducts for turbocharged engines, cooling system pipes, tubes fuel lines, filler pipes, Seamless door handles, off-road vehicle parts, furniture manufacturing, piping and tubing.
Guidelines for 3D Blow Molding
3D blow molding allows the production of intricate automotive components with fewer parting lines, improved wall thickness distribution, and reduced material waste compared to traditional blow molding
3D Blow Molding Guide
3D Blow Molding
3D blow molding technology is very advantageous because its advantages of seamless welding and uniform wall thickness can maintain the overall quality and aesthetic performance of the product. The so-called three-dimensional (3D) blow molding refers to the pre-blow molding of plastic raw materials after extrusion, and making them tightly adhere to one side of the mold wall. Then, the extrusion head or mold rotates the second or third axis according to the manufacturer’s preset molding program. When the intestinal billet fills the membrane cavity, the other side of the mold is closed and tightly fixed to the billet section, separating it from the subsequent billet section. This is when the entire billet is blown and tightly attached to the wall of the membrane cavity for molding. Using this method to produce air ducts or oil pipes similar to those on cars can not only reduce burrs and surface roughness but also enable continuous extrusion without the need for clamping products, making 3D blow molding easier to process many more complex shaped parts.
Various complex automotive components can also be manufactured using 3D blow molding. In some developed countries, 3D blow molding technology has replaced other plastic molding technologies in certain application areas, such as the production and manufacturing of components such as oil pipes and seamless door handles. In addition, the value of 3D blow molding technology in furniture, off-road vehicle component manufacturing, and large-scale water pipe installation is gradually emerging.
The automotive industry has gradually increased its demand for the production of complex and tortuous conveying pipelines, driving the development and progress of off-axis extrusion blow molding technology. This technology is called 3D blow molding, and in some countries, it is also known as multi-dimensional extrusion blow molding MES. Compared to other molding technologies, the waste and burrs generated during 3D blow molding processing are significantly reduced or even non-existent, so this technology is also known as low-waste or no-waste 3D blow molding.
Types of 3D Blow Molding
- Three-dimensional (3D) extrusion-blown hollow plastics are that after the plastic billet is extruded, it is pre-blown and tightly attached to one side of the mold wall. The extrusion head or mold rotates the second or third axis according to the molding program. When the intestinal-shaped billet fills the membrane cavity, the other side of the mold closes and tightly holds the billet, separating it from the subsequent billet. This is when the entire billet is blown and tightly attached to the wall of the membrane cavity for molding. Using this method to produce air ducts or oil pipes similar to those on cars not only reduces burrs but also allows for sequential extrusion without clamping lines on the product, making it easy to process many complex shaped parts using 3D blow molding.
- Adopts a negative pressure forming process that can sequentially open and close the mold. It is to make the upper and lower ends of the mold into sliding blocks that can be opened and closed separately. During production, the mold is closed first. The tubular blank is attracted by negative pressure air and moves along the curve of the inner cavity inside the mold. After the blank is in place, the sliding blocks on the upper and lower ends of the mold are closed and blown into shape; This molding method is more suitable for forming products with regular pipeline shapes.
- Uses robots or robotic arms to hold plastic billets and attach them to the mold, blowing air to form them, and can also achieve three-dimensional blow molding. The conventional blow molding production process is used to produce curved pipe fittings. Because the flat folding width of the billet is much larger than the projection width of the product, a large number of waste edges (some with a height of over 50%) will be generated, and the gap between the billets is longer, which not only affects the appearance but also the strength of the product.
The Advantages of 3D Blow Molding Technology
Compared to traditional blow molding techniques, 3D blow molding has many advantages, such as:
- High-quality blow molding without welds
- More uniform distribution of outer wall thickness
- The welding seam will not have a decrease in firmness due to the accumulation or scoring of raw materials
- Low flash loss and low return rate
- Reduce capital investment in small extruders, clamping devices, and grinders
- Reducing the mixing and cooling of raw materials reduces operating costs
3D Blow Mold Steel Materials
The commonly used materials for 3D blow molding molds include domestically produced 718, P20, 4Cr13, domestically produced S136, 2316, etc; Among them, 4Cr13, domestically produced S136, and 2316 have better wear resistance and chemical corrosion resistance compared to other materials. Manufacturers can choose molds based on the type and usage of the products they produce and can configure automatic trimming functions according to actual processing conditions.
1.718 plastic mold steel has excellent mechanical properties and processability, and its processing technology is simple, so it is widely used in the mold processing and production industry. In addition, the 718 mold steel has undergone a special production process and is pre-hardened to a hardness of 41-47HRC when leaving the factory, which can reduce the heat treatment process in some engineering projects and improve economic benefits.
2.P20 mold steel is a type of mold welding material, suitable for making plastic molds and die-casting low melting point metal mold materials. This steel has good machinability and mirror grinding performance.
3.4Cr13 mold steel has high hardness and good corrosion resistance after quenching. Usage: Used for parts such as hot oil pumps, valve discs, valve bearings, medical devices, plastic molds, plastic mirror molds, springs, etc. with high hardness and wear resistance.
4.The S136 mold material has excellent polishing and polishing performance (mirror processing) through electro-slag remelting, good wear resistance and toughness, and good plasticity at high temperatures. Due to its high chromium content (13.6%), it has excellent corrosion resistance. Pre-hardened and corrosion-resistant mirror mold steel S136 is a mirror anti-rust mold steel.
5.2316 mold steel is a highly corrosion-resistant, highly polished pre-hardened plastic steel with excellent processing performance and excellent machinability. Excellent corrosion resistance, excellent polishing performance, excellent machinability, excellent stability during quenching, suitable for plastic molds that require polishing requirements such as cosmetics molds and stationery molds.
Applications of 3D Blow Molding
- Automotive Industry
The automotive industry has embraced 3D blow molding for the production of critical components that demand exceptional precision and performance. Air ducts, instrumental in regulating airflow and temperature within the vehicle, are meticulously crafted using this process. The seamless nature of these components ensures optimal airflow, contributing to enhanced engine performance and passenger comfort.
Moreover, fuel tanks, which require intricate designs and leak-proof construction, are manufactured through 3D blow molding. This technique allows for the creation of complex shapes while maintaining uniform wall thickness, ensuring structural integrity and safety. Instrument panels, another crucial automotive component, benefit from the design flexibility offered by 3D blow molding, enabling the integration of various features and aesthetically pleasing contours.
- Packaging Industry
The packaging industry has been transformed by the advent of 3D blow molding, which enables the production of lightweight yet robust containers for a wide range of products. From beverages to household chemicals, this process ensures the creation of seamless, leak-proof containers with intricate designs.
The ability to incorporate unique features, such as integral handles and trigger sprays, has revolutionized the way products are presented to consumers. Additionally, the option for dual-layered bottles offers an additional barrier, enhancing product protection and extending shelf life.
- Medical and Pharmaceutical Industries
The medical and pharmaceutical industries have embraced 3D blow molding for its ability to produce sterile, disposable devices and containers. Intravenous (IV) bags, catheters, and respiratory equipment are among the critical products manufactured using this process.
The seamless nature of these products, combined with the ability to maintain precise wall thickness and material purity, ensures patient safety and hygiene. Furthermore, the design flexibility offered by 3D blow molding allows for the incorporation of specialized features, such as calibrated markings and precise dosage measurements, enhancing the accuracy and reliability of medical devices.
- Consumer Goods and Furniture
The consumer goods and furniture industries have also embraced 3D blow molding for its ability to create visually appealing and functional products. From toys and household items to furniture components like armrests and chair legs, this process offers unparalleled design flexibility.
The seamless nature of the products, combined with the ability to incorporate intricate details and textures, has opened up new avenues for product differentiation and branding. Additionally, the potential for parts integration through 3D blow molding has led to cost savings by eliminating assembly steps and reducing the overall number of components.
