Plastic injection molding china

Plastic injection molding china

Plastic injection molding china is a technique through which plastic products are manufactured using the pressure of the molten plastic injected into the mold of plastic products. After cooling these moldings desired variety of plastic parts are obtained. There is specialized machinery for injection molding and the mold is acquired after the resin material is injected into a metal mold apparatus of the products having a certain shape. Often the final product is the resulting shape which requires no installation or processing. There is lot of detailing like convex portion, the ribs, threads that can be molded in the operation of the injection molding process. Read more

High Speed Injection Molding

How do you achieve high-speed production of complex parts?

Answer:

The key component is an understanding of the volumes required. If the volumes are a million pieces per year, sometimes a four-cavity mold is needed or a high-quality tool. For high-speed or high-volume production, using high-quality tools is important. The tools should hold up with very little maintenance in this process.

Given a million pieces per year, a four-cavity small part is appropriate. To reduce the price of the parts as much a possible, hot-runner systems are needed to run high-speed molding. These systems eliminate the scrap from production; therefore, the parts are the sole result of the process.

Given five to seven million pieces per year, multi-cavity molds (eight-, sixteen-, twenty-four, thirty-two-cavity molds) are needed. Hot-runner systems and high-volume tools become very important. It is critical money be invested upfront in the development of this process. Based on the performance of these high-speed tools, the costs will be recovered in the future.

How does involving your mold-maker early in the process impact your engineering and development of new plastic molding products?

Answer:

The mold-makers involved in the trade of high-quality tooling must have several years of experience. The majority of mold-makers go through apprenticeship and training programs sponsored by the state.

Not only have they received state certification, they have trained on the production floor. By observing the production staff, mold-makers gain an understanding of the process and the end result of the types of products manufactured. Performance results are obtained during this exercise.

Getting the plastic mold maker engaged in the beginning also brings up a lot of ideas and develops the thought process for production. Based on their years of experience, it can be systematically determined how to produce high-quality tools with a very small margin of error in molding.

This lends itself to the best product possible with the least amount of down time. It incorporates the types of steels used, the types of molds used, as well as the types of engineering required. Any aspect of the process is accentuated by the experience of the mold-makers and their recommendations. It is crucial they be consulted at the very beginning of product development.

How do you move tools from overseas or execute mold transfers?

Answer:

When transferring plastic molds from overseas, the best practice is to find a facility that has an in-house tooling capability. It is important the facility is able to accomplish large-scale repairs on molds. Therefore, the skills required for execution are available within the company itself.

Since the company receiving the tools or the mold transfer is highly trained, the tools are sent there to be taken apart and examined. This step in the transfer process allows the manufacturer to assess if the tools were properly built. In numerous cases, tools are shipped with a combination of U.S. and European (metrics) supplies mixed together within the same molds.

These are some of the issues that need to be addressed to ensure proper procedures are taken to straighten the tool out. Otherwise, it cannot be made into a moldable product. Another concern is standardization of the molds. The molds should run in standard molding machines built for the industry.

The type of material needed to run in a particular plastic mold – engineering or otherwise – must be a consideration as well. The molds must be capable of meeting the volumes required for the materials involved. Some tools may not have the capacity to run the necessary volumes for the entire duration of the process.

A lot of tooling that comes from overseas may be prototype, not production tooling. The type of steel or engineering used during production may not be standardized or in line with manufacturer expectations. Prototype tools are not designed for high-volume production. It is important the tools are assessed properly.

What are the best practices in new product mold design?

Answer:

After product development has been secured and generation of plastic parts has begun, the best practice is to have those plastic parts designed by an expert. Generally, this would be a trained plastics engineer specializing in the various aspects of the process: tooling, molding, and plastics.

The engineer reviews the product line to confirm the plastic parts are moldable, the material used is appropriate, and the types of machines required. The results of the engineer’s assessment can be interpreted as to whether the product line is capable of being molded or not.

In order to save costs on the front end, work with a plastics engineer that specializes in tooling and molding. Based on this expert opinion, the feasibility of the product line may be determined.

CNC machine

FADAL is known to be one of the leading CNC machine brand. Fadal produces one of the finest quality CNC machines. Fadal offers a wide range of CNC machines varying in designs and makes. Most machines are designed as vertical machine center.

VMC machines are designed for high performance and accuracy. The VMC machines are built for heavy construction and tolerance which also reduces the cycle time of the overall process. Fadal CNC machines offer many unique features such as spindle drive systems. Fadal also offers simple CNC machines for regular operations which do not involve complexity.

Fadal has also introduced the FX series of CNC machines will are even more advanced and expensive and also includes various features such as low cycle times and high machining performance. The Fadal CNC machine saves both time and money because of its high production and quality. Fadal CNC machines are considered to be one of the best CNC machines in the market. Stay tuned to SINCERE  TECH for more information, ST has many CNC machines and is A mold manufacturer China company

 

Injection molding machine barrel cleaning

Injection molding machine barrel cleaning

The exits of buildup in injection machine barrel when we start to operator injection machine will influence the plastic product quality. So in order to guarantee the plastic product quality, injection machine barrel cleaning is very important.

  • Method of injection machine barrel cleaning

1)      If injection machine want to manufacture many kinds of product, we should manufacture the product with light color, low melt temperature and bad heat stability, thus changing the material, cleaning the barrel is very easy.

2)      When the new material temperature is higher than unused material temperature, we should increase the injection machine and nozzle temperature to the lowest process temperature which new material need.

3)      If the new material molding temperature lower than unused material in injection machine barrel, we should increase the injection machine barrel temperature, then cut the heating power when the unused material in a certain condition.

4)      For the injection machine barrel cleaning of unused material with heat sensitivity, like PVC,POM,PCTFEF3 and so on, to avoid plastic decompose, we can adopt two stages, that is using plastic with good heating stability to transition refueling cleaning first ,like PS,LDPE and so on, then use the new material to replace the transition cleaning material.

5)      Use cleaner to clean the injection machine barrel.

No matter change the material directly or transition refueling, they will cost many material. Using cleaner to clean the injection machine barrel can not only save the cost but the effect is good. It is suitable for the injection machine barrel cleaning which process temperature range from 180℃ to 280℃.

Good plastic injection molding parts made by good quality plastic mold

  •  Pattern of injection machine barrel cleaning

1)      Plunge type injection machine barrel cleaning

Since big quantity stores, cleaning the injection machine barrel is very difficult, we must use special injection machine barrel.

2)      Screw injection machine barrel cleaning

Generally, we use changing material cleaning directly, we should know the temperature range of unused material in injection machine barrel and the heating stability first, and then we can set specific cleaning pattern easily

Injection Molding Process

Injection Molding Process

The injection molding process parameters of two kinds of commonly used plastic reference,

A, high density polyethylene (HDPE)

Barrel temperature feeding zone 30 ~ 50 C (50 DEG C)

From 1160 to 250 C (200 DEG C), from 2200 to 300 C (210 DEG C), from 3220 to 300 C (230 DEG C)

From 4220 to 300 C (240 DEG C), from 5220 to 300 C (240 DEG C), the nozzle 220 ~ 300 C (240 DEG C)

Temperature is suggested in brackets as the basic set value, travel utilization rate was 35% and 65%, mold flow length and wall thickness ratio of 50:1 to 100:1

Melt temperature 220 to 280 DEG C, barrel temperature of 220 DEG C, mold temperature of 20 to 60 DEG C

With good flow property of injection pressure, avoid the use of high injection pressure 80 ~ 140MPa (800 ~ 1400bar); except for some thin wall packaging container can reach 180MPa (1800bar).

Holding pressure contraction degree is high, need long time on the product pressure is maintained, the dimensional accuracy is the key factor, the injection pressure is about.30% ~ 60%

Back pressure 5 ~ 20MPa (50 ~ 200bar); back pressure too low place is easy to cause the weight of the product and the dispersion.

High injection speed injection speed of thin-wall packaging containers need, secondary injection speed is often applied to the plastic products of other classes.

Screw speed high screw speed (line speed is 1.3m/s) is permitted, as long as meet the cooling time before the end of the completion of the plasticizing process can; screw torque requirements for low.

Measurement of travel of 0.5 ~ 4D (minimum to maximum); metering stroke4D for the melt dwell time is long enough to provide the residual material amount is very important for 2 ~ 8mm, depending on the measurement of travel and the screw diameter.

injection molding cost is depending on the molding process

The recovery rate can reach 100% recovery.

The shrinkage rate of 1.2 ~ 2.5%; easy to twist the high degree; shrinkage;never shrink after 24h (after shrinkage)

The gating system point gate; heating hot runner hot runner, insulation, cast in suit; cross-sectional area is relatively small, the thin section products have enough machine stoppage time without the need to use other materials for cleaning work of specialized PE temperature rise;

Barrel equipment standard screw, three section type screw standard us on the packaging container products, mixing section and shear section geometric shape special (L:D = 25:1), through the nozzle, a non-return valve.

Two, polypropylene (PP)

Barrel temperature feeding zone 30 ~ 50 C (50 DEG C)

From 1160 to 250 C (200 DEG C), from 2200 to 300 C (220 DEG C), from 3220 to 300 C (240 DEG C)

From 4220 to 300 C (240 DEG C), from 5220 to 300 C (240 DEG C)

The nozzle 220 ~ 300 degrees (240 degrees C)

Temperature is suggested in brackets as the basic set value, travel utilization rate was 35% and 65%, mold flow length and wall thickness ratio of 50:1 to 100:1

Melt temperature 220 to 280 DEG C, barrel temperature of 220 DEG C, mold temperature of 20 to 70 DEG C

With good flow property of injection pressure, avoid the use of high injection pressure 80 ~ 140MPa (800 ~ 1400bar);

Except for some thin wall packaging container can reach 180MPa(1800bar).

Holding pressure to avoid product shrinkage wall, take a long time for the product of holding pressure (about cycle time; 30%) about the injection pressure 30% ~ 60%.

Back pressure 5 ~ 20MPa (50 ~ 200bar).

The injection speed high injection speed of thin-wall packaging containers need (accumulator); secondary injection speed is often applied to the plastic products of other classes.

Screw speed high screw speed (line speed is 1.3m/s) is permitted, as long as meet the plasticizing process cooling time before the end of May.

Measurement of travel of 0.5 ~ 4D (minimum to maximum); metering stroke4D for the melt dwell time is long enough to provide is very important

Residue volume ranged from 2 to 8mm, depending on the metering stroke and screw speed.

Pre drying is not needed; if the storage condition is not good, at a temperature of 80 DEG C dried 1H can.

The recovery rate can reach 100% recovery.

The shrinkage rate of 1.2 ~ 2.5%; contraction degree is high; won’t shrink after 24h (after shrinkage).

The gating system point gate or multiple point gate; heating hot runner hot runner, insulation, cast in suit; the position of gate WIP thickest point, or prone to large shrinkage.

injection molding China company needs optimize the parameter from time to time to reduce the cost and keep same quality.

Machine stoppage time without the need to use other materials for cleaning work of specialized PP temperature rise;

Barrel equipment standard screw, three section type screw standard use on the packaging container products, mixing section and shear section geometric shape special (L:D = 25:1), through the nozzle, a non-return valve

What is Insert Molding

What is Insert Molding

While the injection molding as well as insert molding processes are more or less the same, the only difference is that the injection molding makes use of only thermoplastic materials. On the other hand, this process can make use of plastics as well as other metals in order to manufacture and produce even better or advanced products. This process has become so very popular these days that it gives various advantages to people. The application of this kind of molding is far, wide and advantageous to a lot of extent.

This can be called a highly advanced and better process in which the components or parts such as bushings, metal stampings, filtration materials, electromechanical parts as well as various distinct parts are joined or rather combined into one component only with the help of thermoplastic injection into ‘inserts’ or the placed parts. Read more