The Best Solution for Plastic Injection Molding
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 technology is the best solution for plastic production, which can produce high-quality and high-precision plastic products. At present, injection molding technology provides many solutions for defects in processing.
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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Manufacturing problems often occur during the plastic injection molding process, which is the fundamental reason for product defects or quality issues. To ensure the quality and performance of the final product, manufacturers need to combine their experience with the actual situation, analyze the causes of defects, and propose corresponding solutions to prevent further problems from occurring and improve the production efficiency and product quality of injection molding.
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During the process of plastic custom injection molding, the produced parts are prone to defects such as roughness, cracks, burrs, and discoloration. Manufacturers have proposed corresponding solutions based on these defects.
The Product is Rough
-Reason
- The plastic injection mold cavity is rough and has poor smoothness
- Plastic contains too much moisture or volatile substances, and has not been dried in advance, or plastic pigments have decomposed and deteriorated
- Insufficient supply, poor plasticization, or decreased plastic flowability
- Plastic injection molding molds have moisture and oil stains on their walls
- Excessive use or improper selection of release agent
- The molten material is not completely in contact with the cavity wall inside the mold cavity
- Slow plastic injection molding speed and low pressure
- Small demolding slope, poor demolding or low surface hardness of the product, easy to scratch and wear
- Uneven particle size, or mixing of incompatible materials resulting in uneven color, silver threads, etc
-Solutions
- Polish the mold cavity again
- Dry plastic raw materials, use recycled materials reasonably and prevent impurities from being added
- Check the condition of the discharge port and the plasticization of the plastic material, and then adjust the parameters
- Clean and repair water leaks, and cracks or prevent condensation of water vapor on the wall, and wipe off oil stains
- Choose a small amount of release agent correctly and clean the mold
- Improvement can be achieved by increasing the injection pressure, raising the mold temperature, and increasing the feeding material
- Increase the injection pressure and speed setting, increase the melt adhesive temperature, and increase the back pressure
- Modify the inclination of the mold, select the needle parameters reasonably, and carefully operate during the operation
- When mixing, pay attention to the uniform size of the particles to prevent other materials from entering by mistake
Product Crack
-Reason
- Plastic is contaminated, poorly dried, or has volatile substances
- The large mixing ratio of plastic and recycled materials results in excessive directional shrinkage of the plastic or uneven distribution of fillers
- Inappropriate demolding design, thin product wall, small demolding slope, sharp corners and gaps, easy stress concentration
- Improper positioning of the ejector pin or ring, improper molding conditions, excessive stress, and poor ejection
- The mold temperature is too low or uneven
- The injection pressure is too low and the injection speed is too slow
- The injection time and holding time are set too short
- Improper adjustment of cooling time, too long or too short
- Uneven cooling after demolding or post-treatment of the product, or improper use of demolding agent
-Solutions
- Check whether the plastic is contaminated with impurities, etc
- Strictly control the proportion of plastic recycling and waste mixing, so that the plastic can be well plasticized
- Modify the mold design to eliminate small slopes, sharp corners, and gaps
- Adjust and install the ejector pin device to ensure that the ejector pin can smoothly push out the product without collision
- Adjust the mold temperature to maintain normal or increase the mold temperature
- Increase the set values of injection pressure and speed parameters
- Increase the setting of injection time and holding time parameters
- Adjust the cooling time reasonably according to the specific situation of the product
- Reasonably use release agents to ensure even cooling of the product after demolding
Product Flying Edge
-Reason
- Plastic temperature and mold temperature are too high
- Injection molding pressure too high or plastic flowability too high
- Asymmetric or uneven locking force on both sides of the mold
- The template is unbalanced or the guide column is deformed, resulting in poor parallelism of the mold
- The plastic injection molding time is set too long
- There are obstacles at the mold edge, causing poor sealing of the parting surface, or sliding of the cavity and core parts, resulting in excessive clearance between parts
-Solutions
- Reduce the heating cylinder temperature and mold temperature of plastic injection molding equipment
- Reduce the injection pressure or speed
- Adjust the symmetry of the tooling and mold, and adjust the locking force parameters
- Adjust and verify the balance of the mold and template to ensure that the forces on all four sides are balanced
- Reduce the setting of injection time parameter values
- Clean or polish the mold edges, repair and replace parts with excessive gaps
Product Discoloration
-Reason
- Impurities mixed into plastics and pigments
- Plastic and pigment pollution or degradation, decomposition
- Poor pigment quality or uneven mixing during use
- The temperature of the material barrel and nozzle is too high, causing the rubber material to burn and discolor
- The pressure and speed of plastic injection are set too high, causing additives and coloring agents to decompose
- The surface of the mold has moisture, oil stains, or excessive use of release agent
- Uneven distribution of fiber fillers leads to resin dissolution when the product comes into contact with solvents, exposing the fibers
- There are obstacles in the glue barrel that promote material degradation
-Solutions
- Avoid mixing impurities during mixing
- The raw materials used for injection molding should be dry, the equipment should be clean, and they should be cleaned thoroughly when changing materials to avoid leaving excess material
- Ensure the quality of the pigments used, and the pigments should be evenly attached to the surface of the particles during mixing
- Reduce the temperature of the melt adhesive and nozzle, and remove burnt adhesive material
- Reduce the injection pressure and speed parameter values to avoid additive decomposition
- Wipe off the surface moisture and oil stains of injection molding molds, and use release agents reasonably
- Reasonably set the process parameters of fiber fillers, use solvents reasonably, achieve good plasticization, and eliminate fiber exposure
- Pay attention to eliminating obstacles, especially strictly following the step-by-step procedure for material replacement, or use the transitional material replacement method
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Applied’s expertise in modifying materials at atomic levels and on an ihdustrial scaleenables our customers to transform possibilities into reality.
The injection molding process is a method widely used in the production of plastic products. It injects molten plastic material into a mold of a specific shape, cools, and solidifies to form the desired product.
Modern mould making company is committed to the design and development of molds, with the updating and replacement of plastic products, mold manufacturing technology is also constantly advancing.
Some companies providing automotive injection molding services have an experienced design and operation team, as well as advanced custom injection molding production technology.
