Plastic Injection Molding Company
Plastic Injection Molding
Details
Details:
Model
Material
Brand
Origin
Application
Booling-Injection-1
P20, 718, S136, 2738 etc
Booling
China
Automotive parts, industrial parts, medical parts, household
Plastic injection molding, under the pressure and heating of injection molding machines and molds, melts and plasticizes the plastic to form the desired shape and structure, meeting the requirements of complex shapes and structures. It is an efficient manufacturing technology.
Advantages of Plastic Injection molding：
- High Precision and Repeatability
- Low Cost per Part
- Fast Production Rate
- Wide Material Choice
- Little Waste
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The common methods used by a plastic injection molding company to process thermoplastic plastics include extrusion,injection molding, rolling, blow molding, and thermal molding. Processing thermosetting plastics generally involves molding, transfer molding, and injection molding. The choice of plastic molding method by a plastic molding company depends on the type of plastic chosen (thermoplastic or thermosetting), the initial form, and the shape and size of the product. Plastic molding is the process of making various forms of plastic (powder, granules, solution, and dispersion) into desired-shaped products or blanks. There are over thirty methods of forming. Lamination, molding, and hot forming are processes that shape plastics on a flat surface. The above plastic processing methods can be used for rubber injection molding process. In addition, there are also casting processes using liquid monomers or polymers as raw materials. Among these methods, extrusion and injection molding are the most commonly used and also the most basic molding methods.
The main responsibility of a plastic molding company is to select the appropriate molding method for plastic raw materials by measuring products and molds and to produce products or blanks of the desired shape from various forms of plastic (powder, particle, solution, and dispersion).
Plastic Molding Process
A plastic molding company needs to measure the process of plastic raw materials and products to determine whether to provide blow molding or injection molding services. The following are various plastic molding methods and their advantages and disadvantages:
- Injection Molding
Injection molding is a method of uniformly plasticizing plastic raw materials in a heated cylinder, and then pushing them into the closed mold cavity by a plug or screw for molding. This method has a fast production cycle, low injection molding cost, high production efficiency, and can shape products with complex shapes, precise dimensions, or embedded parts. There are many types of plastic molded, making it easy to achieve automation. However, the price of injection molding molds is the highest among all molding methods. At present, manufacturers of injection molds are developing this technology towards higher speed and automation. At present, the injection molded products produced by plastic molding companies mainly include the shells of refrigerators, washing machines, air conditioners, water dispensers, etc.
- Extrusion Molding
Extrusion molding is the process of continuous production of polymer material melted through a mold with a certain shape under the extrusion action of the screw in the extruder. This method can achieve continuous molding, high yield, and high production efficiency; The formed product is a continuous profile with an unchanged cross-sectional shape, with a simple appearance, uniform and dense quality, small anisotropy, and relatively accurate dimensions. Mainly used in the production of plastic products such as pipes, bars, sheets, plates, profiles, films, single fibers, flat tapes, wires, and cables.
- Blow Molding
Blow molding mainly refers to hollow blow molding (also known as blow molding), which is a method of using gas pressure to blow and expand the hot melt blank closed in the mold to form hollow products. The cost of blow molding molds is lower than that of injection molding, and the production cost of products is also lower; The residual stress of the product is relatively low, with good toughness, impact resistance, and adaptability to the environment, and it has good performance in use; Blow molded products produce fewer burrs and require fewer repair processes, resulting in lower costs compared to injection molding. However, in this processing step, if the temperature has a significant impact, there may be adverse consequences such as uneven wall thickness or easy breakage of the product.
Process Characteristics of Plastic Molding
A plastic molding company and mold manufacturer should consider the characteristics of plastics during processing to avoid a series of problems such as a shortage of materials and meat in plastic-formed products, which can increase manufacturing costs. For example, the process characteristics to consider include shrinkage rate, fluidity, specific volume and compression rate, hardening characteristics, moisture and volatile matter content, etc.
Shrinkage Rate
The property of dimensional shrinkage occurs when a plastic part is taken out of the mold and cooled to room temperature, which is called shrinkage. Because shrinkage is not only the thermal expansion and contraction of the resin material itself but also related to various forming factors, the shrinkage of the formed plastic part should be called forming shrinkage.
Liquidity
The ability of plastic to fill the mold cavity at a certain temperature and pressure is called fluidity, which is an important process parameter that must be considered in mold design. If the fluidity is too high, it is easy to cause an increase in overflow, the filling cavity is not dense, the plastic structure is loose, the resin and filler accumulate at different ends, it is easy to stick to the mold, demolding and cleaning are difficult, and there are defects such as premature hardening. However, if the fluidity is too low, it can lead to insufficient filling, difficulty in forming, and high forming pressure. Therefore, the fluidity of plastic must be suitable for the requirements of the plastic parts, forming process, and forming conditions. When designing molds, the pouring system, parting surface, and feeding direction should be considered based on the flow performance.
Specific volume and compression rate
Specific volume is the volume occupied by each gram of plastic (measured in centimeters ³/gram). The compression ratio is the ratio of the volume or specific volume of plastic powder to plastic parts (which is always greater than 1), and both can be used to determine the size of the mold loading chamber. The larger the value, the larger the volume of the loading chamber. At the same time, it also indicates that the excessive inflation inside the plastic powder can cause difficulty in the exhaust, and the long forming cycle can lead to low productivity. If the specific volume is small, the opposite is true.
Hardening characteristics
During the processing of a plastic molding company, thermosetting plastics transform into a viscous plastic flow state under heating and pressure, increasing their fluidity to fill the mold cavity. At the same time, condensation reactions occur, and the crosslinking density continues to increase. The fluidity rapidly decreases, and the plastic in the molten state gradually solidifies. When designing molds for plastics that harden rapidly and are difficult to maintain in a flowing state, attention should be paid to making loading, unloading, and inserting parts as convenient as possible, and selecting reasonable forming conditions and operations to avoid premature hardening or insufficient hardening, which may lead to incomplete plastic forming.
Moisture and volatile matter content
The moisture and volatile content of different plastics are not the same. When the content is too high, they have greater fluidity, high possibility of overflow, long holding time, increased shrinkage, and are prone to adverse effects such as ripples and warping, which affect the mechanical and electrical properties of plastic parts. But when plastic is too dry, it can also lead to poor fluidity and difficulty in forming. Therefore, different plastics should be preheated and dried according to requirements, especially in humid seasons. For materials with strong moisture absorption, even after preheating, corresponding measures should be taken to prevent further moisture absorption.
The company's Maintenance of Plastic Molding Machines
To reduce the cost of plastic molding, the plastic injection molding company and manufacturer need to regularly maintain and upkeep plastic molding machines, including:
- Electrical Control Part:
The traditional plastic molding machine used by a plastic molding company relies on contact relays to switch various actions, so the contact screws are prone to loosening and the contacts are prone to becoming brittle due to aging and failure. Usually, after one million uses, new products should be replaced to ensure the normal operation of the electrical control part throughout the entire machine. The environmental factors that affect the operation of the machine mainly include dust adhesion and humid air.
Modern plastic molding machines use contactless integrated circuits, greatly reducing the connection of wires, significantly improving the adverse effects of wire faults, and enhancing their stability during use.
- Institutional Part:
The institutional part should be regularly maintained and lubricated to reduce friction coefficient and wear. The nuts and locking screws on the headboard should be inspected regularly to prevent the column from being subjected to uneven force and breaking.
The mold thickness adjustment mechanism should be regularly checked for any deviation or looseness in the large gears or chains of the transmission shaft. Whether the screws on the pressure plate of the gear are loose, and whether the lubricating grease is sufficient.
- Oil Pressure Part:
In terms of the oil pressure system, clean hydraulic oil should be used to ensure its quality. Hydraulic oil with good stability and high quality should be used. In addition to regular replacement, to avoid affecting the stability of oil pressure action due to deterioration, its working temperature should be appropriately controlled below 50 ℃.
Repair or Replace
- Repair: Identify the cause of the malfunction, repair the plastic molding machine malfunction, and take preventive measures; Check the relevant parts to prevent the spread of faults.
- Replace: Correctly assemble, debug, and replace parts, and pay attention to the components related to this part. The replaced parts should be repaired or scrapped promptly according to the degree of damage.
- Conduct performance testing
- Record and Provide Feedback
Collect valuable information and data on plastic molding machines, such as the time of occurrence, symptoms, downtime, repair hours, parts replacement, repair effectiveness, unresolved issues, outstanding expenses, etc., and store them in archives according to prescribed requirements.
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