Injection moulding Design

There are two areas of consideration in designing for injection moulding

Production Considerations

Plastic Injection moulding is a heat process and plastics are poor conductors of heat, that is to say it takes a relatively long time for plastic parts to cool down. With this in mind the aim should be to keep sections of parts as thin as possible, this will not only mean shorter moulding cycle times but also less material content.

Strength – If the part needs some strength this can be achieved by the addition of ribs rather than thickening of the section. With plastics, thicker sections do not necessarily mean stronger parts, in some instances beyond a certain thickness the part can become more brittle due to the resulting lack of flex.

Material– Another consideration is choice of material type and grade. Thermoplastics can range in price from just over £1 per kg for basic polyolefins up to £25 per kg and beyond for PEEK and other specialised polymers. By designing strength into a part it may be possible to use a cheaper material but sometimes the reverse can be true and advice should be sought from the moulder.

The price of polymers is also governed to a certain extent by the amount purchased so some benefit may be gained by using a grade already used by the moulder. Be guided by the moulder rather than sticking rigidly to a specified grade.

Eliminate Assembly– If a number of parts are required, and especially when converting from metal or a different production method, look at the possibilities of combining two or more parts into a single moulding so eliminating assembly. It is often possible to produce complex single mouldings that would not be possible with a different method of production. In a similar vein, where assembly is required every effort should be made to make this as simple as possible with the use of snap-fits, for example.

Injection Moulding
Injection Moulding

Tooling Considerations

Combining Parts Injection mould tooling is relatively expensive but it is not always correct to assume that it is only suited to long production runs. If it is possible to combine a number of parts into a single moulding, for example, then the cost of assembly and possible other ancillary parts can be saved making shorter production runs economical.

Keep it Simple– The simpler the mould tool the lower the cost. If possible avoid holes in side walls of parts, undercuts and other complex features. The mould tool can then be what is referred to as straight open and close. If the part does need side holes, for example, then these can either be moulded in which would require side movements in the mould tool, or a secondary operation will be necessary. Which approach is adopted will depend on anticipated quantities of the part – the higher the number of parts required the more economical it is to have the features produced by the mould tool rather than as a secondary operation.

The same rule applies to threads. Internal threads can of course be tapped afterwards but the usual method is to have them moulded in. This can be achieved in two ways, either with hand loaded cores or with auto unscrewing in the mould tool. The former requires operator intervention during the moulding process so adding to the part cost whereas the latter means the mould tool can be run fully automatically but will mean a higher tooling cost at the outset.

Multiples– To reduce both total tooling and part costs where a number of similar parts are required in equal quantities and in the same material, it may be possible to produce a family tool, i.e. all the parts moulded in a single cycle from a single tool. Also, where large quantities of a part are required, a multiple cavity tool could be used, i.e. two or more of the same part produced in a single cycle. Although the tooling cost would be higher than for a single impression tool, the part price will be lower so making it cost effective. The moulder can advise on the optimum configuration.

Conclusion

There are a number of factors that impact upon part and tooling cost: material selection, section of part, complexity of design, etc. What is certain is that the further down the design/production cycle you are the more costly any alterations become. Therefore, it is advisable to get the initial design right for injection moulding and to this end you should involve your injection moulder at the very early stages of the project to ensure correct design and material selection for the given application.

PC plastic molding

PC plastic molding– Polycarbonate plastic molding

  • Polycarbonate plastics, including polycarbonate baby bottles and kitchen storage containers, are safe and convenient for the preparation and storage of all types of foods and beverages.
  • Polycarbonate food containers help preserve freshness and protect food from contamination.
  • Polycarbonate plastics are regulated by the U.S. Food and Drug Administration (FDA) and international safety regulations to assure their safety in direct food and beverage contact.
  • A raw material used in polycarbonate plastics, bisphenol A (BPA), has been the subject of recent news reports questioning its safety. The fact is that BPA has been extensively studied for decades. Based on numerous safety tests, the U.S. FDA permits the use of BPA in polycarbonate packaging for all types of food.
  • One 1997 FDA study focused on BPA used to make polycarbonate baby bottles. The study concluded that, in conditions representing typical consumer use, there was no migration at all of BPA from the bottle into its contents. Another study conducted in 1997 by the U.K. Ministry of Agriculture, Fisheries and Food “conclusively demonstrated that there is no leaching of bisphenol A from polycarbonate baby bottles during use.”
  • For technical information on polycarbonate plastic molding ( PC plastic molding ) and its building block material, BPA, visit https://www.plasticmold.net/

Thermoset Transfer Molding

Plastic Molding Manufacturing

Plastic Molding Manufacturing

SINCERE TECH is the most excellent plastic molding manufacturing company. This mold company has different group team members in order to solve the consumer molding problem. One of the most important things is that this company has well qualified and knowledgeable designers. This company not only offer plastic molds, but they also offer plastic mold tooling equipment, molding machine, molding services, plastic mould training and more. The plastic mold tooling equipment is available in all sizes, models as well as shapes. So, consumer can choose the equipment as per their preferred styles. Every consumer can get the molding machines through this company only, because this company only provides endless solutions for molding machines.

Each and every part of the molding machines is tested by utilizing different kinds of equipments. After that only they can deliver the machine to the consumers. This mold company can provide the mold products with full warranty and guarantee. If the customer wishes to get the molding machine, they can simply sit in their home and order the machine name through the mould company website. The Mould Company will deliver the machines from the comfort of office or home. One main thing is that this company will provide all the plastic molded products at very reasonable rate. This company can complete the project within deadline. If the machine will get repaired means no need to worry. The mould company will send the talented engineers to their industry. This engineer will quickly repair the machines problem at free of cost. This company will produce only branded products to the consumers.

If the consumers want to know more information regarding the Plastic Molding Manufacturing Company, they can refer through the company website -https://www.plasticmold.net/