Tool craft plastics

/0 Comments/in , , , , , /by
  • This tool is essentially a metal mold which has a cavity in the shape of the part or component that needs to be produced. The tool is built from hardens and plated steel aluminum blend and is worn up and over to outcome many consistent versions of the equal section.
  • A mold effect tool has multiple craters and can crop several components from the equal specific injection.
  • The plastic / polymer are injected under pressure into the mold tool.
  • The tool is held closed under pressure until the plastic material cools and sets hard in the mold tool cavity.
  • The screw starts to move back for the next molding, the tool then opens and finished plastic part is ejected. The tool is closed and the injection molding process starts again.

What about the environmental impact of plastic?

We often hear about the many negative aspects of e.g.

  • Pollution from plastic that has not been recycled/has ended up as litter on land and in the sea.
  • Worries about the non-biodegradable nature of many plastic.
  • The fact is that the resilience, durability, strength and flexibility of plastic are some of the main reasons why they are so useful to us. Progress is being made in creating biodegradable plastic products e.g. food bags for recycling and carrier bags.
  • Laws, regulation and targets to reduce landfill and promote recycling domestically and commercially are now having a major positive effect on how we deal with plastic waste products. Approximately one quarter of the plastic we use is now being recovered and recycled and this number is steadily increasing over time.

There are also many positive environmental aspects to plastics and plastic molding manufacturing including:

  • Advances in engineering technology mean that injection molding machinery now uses 20%-50% less energy compared to 10 years ago.
  • The lightweight nature of plastic relative to alternative materials means that it keeps down the weight of the products that it’s used in. In the case of aircraft and road vehicles this can translate into fuel and energy savings.
  • The effectiveness of plastic insulation materials in buildings such as Expanded Polystyrene (EPS) helps save energy and money.
  • Plastics are used extensively in double glazing and renewable energy products and therefore help to save and produce energy.
  • Plastic injection molding is a vital process in manufacturing with benefits for the UK economy and the environment as well as our daily lives.

Vacuum forming

  • Vacuum found or thermoforming associated a bitter surface of plastic vitality stretched onto or into a specific shallow mold. The heated plastic sheet is held against the mold by applying a vacuum between the mold surface and the sheet.

The vacuum forming process

  • Once the correct vacuum forming tool is loaded into a vacuum forming machine, plastic forming can be produced using the following process:
  • The vacuum forming tool is warmed.
  • Plastic either in roll or sheet form is fed into the material carrier of the vacuum forming machine.
  • The heaters raised the plastic piece, heat the plastic element until it converts soft.
  • The softened sheet of heated plastic is leveled automatically using air.

Plastic injection molding inspection guide

/0 Comments/in , , , , /by

What to expect in this article

  • Tool design
  • Ejector pin positioning
  • Machine set – up tool change over
  • Required inspection equipment
  • First off inspection report

Start with tooling design

What is tool design?

Every plastic part designed to be injection molded needs to be produced from a tool also known as a die. These tools need to be designed using computer-aided design (CAD) software and the design engineers need to have a full understanding of how to design a tool that will produce the required part to specification.

What level of detail to check for?

Every part is different, therefore every tool would be different, and however, there are some common aspects to all tools that should be relatively standard. These standard parts of the tool design are important, however, we should be checking for more specific detail which includes the following

  • Gate type, position and size
  • Balanced runner system
  • Ejector pin position
  • Any sliders or moving cores
  • Mold flow analysis (if carried out)

Ejector pins

Ejector pins apply force to eject apart from the mold and it is important that the position and size of the ejector pins is taken into consideration during the design stage

Machine set – up checklist

What is the machine set – up?

Every time a new job is run, there is the need to do a changeover of tools. This means taking the current tool out of the molding machine and placing the next required tool into the machine. This set – up process should be carried out in the absolute any mistakes or errors.

This is why a checklist should be followed.

A set – up that has errors can lead to sluggish cycles, high scrap rats, tool damage, flawed parts, rework, an unsteady process and delayed product de delivery.

Ultimately, this all leads to higher reject rates!

Inspection equipment required

What is equipment is required?

Plastic injection molded parts are produced for numerous reasons and application, some can be cosmetic where tight tolerances are less important than the surface finish, whereas others are heavily reliant on tight tolerance dimensions being correct every time.

Must have equipment?

Molded plastic components would need inspection even it is just the first of sample for approval, the following list measuring equipment is a must in any injection molding supplier QC area:

  • 3 coordinate measuring machine (CMM)
  • Set of micrometers
  • Vernier calipers
  • Slip gauges (slip blocks)
  • Surface table
  • Height gauge
  • Dial test indicators (DTI)

First of the sample report

What is a first off sample report?

The first off sample report is a report that records the physical measured dimensions from a product that has been molded from the first pre – production conditions and to measure a number of sample on every dimension to enable verification that the parts are being molded to specification.

Note

There are different names or terms for this report, but they all refer to the same thing. It is a confirmation process to verify parts and/or materials are compliant to all requirements and specification detailed on the blueprint, quality standard and all related standards.

Rubber Injection Molding

/0 Comments/in , , , , , /by

Understanding the Process of Rubber Injection Molding

There are two types of rubber available in the market: these are the natural and synthetic rubber. Rubber has been around for more than hundreds of years now and it has already been used by most of the industrial companies in creating different kinds of materials. Since rubber has played an important role in our life, the process of creating it has been improved using the rubber injection molding.

The main function of rubber injection molding is to process rubber parts, which is being used in machines and other mechanical parts. It comes in different sizes that will fit in various components. It is usually found in press shop and other industrial companies.

Rubber injection molding
Rubber injection molding

The process used in rubber injection molding is not that hard because it will all depend to the machine. The process will begin by acquiring the rubber’s design using a mold that is made from a metal that has an exact size and dimension as the rubber part. This mold is being inserted in a press that is connected in a system called the rubber injection. Once the mold is already inserted to the press, appropriate pressure is being applied. The rubber will be injected to the mold using a screw or a large ram. Through the nozzles, it will be passed into the mold cavity where it is being cooled down. As the process of cooling the rubber goes, it will slowly separate from the mold, while it acquires the design of the mold.

Rubber silicone molding parts does not have any heater elements applied. The process of injection press allows the rubber to acquire the specific design of the mold, which is commonly made from stainless steel. There are two types of rubber injection molding these are the vertical and the horizontal molds. Both have their own advantages and disadvantages when it comes to its process.

Thermoset Transfer Molding

/0 Comments/in , , , , , , , , , , /by
Read more