New technology innovation and application of injection molding

 

New technology innovation and application of injection molding

 

What are the new technologies in plastic injection molding?

1, Gas-Assisted Injection Molding
2, Foam Injection Molding
3, Hot and Cold Runner Molds
4, Insert molding or Over Molding

Industries that thrive on its manufacturing process are no strangers to the technique of plastic injection molding. The overall process of manufacturing is aided by the accuracy of plastic injection molding.
It has gone a long way since its first appearance in the production process in the 1800s. Since then, plastic injection molding has developed into new technologies that enable. You to produce high-quality products and quick manufacturing of plastic parts.
Exploring new technologies in plastic injection molding will do wonders for your business. And for the production of your concept of a product. With these new techniques. The design and function of your plastic parts will be efficient.
If you would like to know the latest plastic injection molding technologies, then this article is for you!

Injection molding is a constantly evolving technology, with new innovations and applications emerging all the time. Here are some recent technology innovations and applications of injection molding:

Additive manufacturing:

Additive manufacturing, or 3D printing, is being used in conjunction with injection molding to create complex molds and parts. This technology allows for rapid prototyping and customization, as well as the creation of unique shapes and designs.

Micro-injection molding:

Micro-injection molding is a specialized form of injection molding that is used to produce very small parts with high precision. This technology is being used in the medical industry to create components for surgical instruments, as well as in the electronics industry to produce miniature connectors and sensors.

Multi-component molding:

Multi-component molding, also known as overmolding, is a process that allows for the creation of parts with multiple materials or colors. This technology is being used in the automotive industry to produce parts with soft-touch surfaces and in the consumer goods industry to create products with unique designs and textures.

Sustainable materials:

Injection molding is being used to produce parts and products using sustainable materials such as bioplastics and recycled plastics. This technology is helping to reduce the environmental impact of manufacturing and increase the use of renewable resources.

Overall, injection molding is a versatile technology that is being used in a wide range of industries and applications. Ongoing innovation and development are helping to improve the process, reduce costs, and increase efficiency.

Does all injection mold need a hot runner?

 Injection molding is a widely used manufacturing process in various industries. It involves injecting molten material into a mold cavity to create a desired shape. One of the key considerations in injection molding is whether or not to use a hot runner system.

A hot runner system is a set of heated components that deliver molten material to the mold cavity. It consists of a manifold, nozzles, and heaters that keep the material hot and flowing. The purpose of a hot runner system is to eliminate waste and improve efficiency. By keeping the material hot and in a constant flow, there is less material waste and shorter cycle times.

However, not all injection molds require a hot runner system. The decision to use a hot runner system depends on several factors, including the size and complexity of the part being molded, the material being used, and the production volume.

For small parts with simple designs, a hot runner system may not be necessary. Cold runner systems, which use unheated channels to deliver the material, may be sufficient. Cold runner systems are generally less expensive and easier to maintain than hot runner systems.

For larger parts with complex designs, a hot runner system may be necessary to ensure proper filling of the mold cavity. Hot runner systems can also help prevent defects such as warping, sink marks, and flow lines.

The material being used also plays a role in the decision to use a hot runner system. Certain materials, such as thermoset plastics, may require a hot runner system to prevent premature curing or solidification.

Finally, the production volume must be considered when deciding whether or not to use a hot runner system. Hot runner systems are generally more expensive to purchase and maintain than cold runner systems. If the production volume is low, it may not be cost-effective to use a hot runner system.

In conclusion, not all injection molds require a hot runner system. The decision to use a hot runner system depends on several factors including the size and complexity of the part being molded, the material being used, and the production volume. It is important to carefully consider these factors when deciding on the best injection molding process for your specific application.

Custom insert molding

 

Various insert molding part use in all industry

Insert Molding (or insert moulding) in China is similar to multi-shot molding in that it results in the combination of two or more resins into a single product. Each resin is molded separately in an individual mold. And is transferred either by a robot or manually to subsequent molding operations for the additional resins. Insert molding is better suited for lower volume applications than multi-shot molding due to lower capital investment requirements. Typical applications include ‘soft-touch’ materials molded onto an enclosure (drill housing or handle) or multiple colors/materials molded together for aesthetic or functional purposes. we have broad experience in the development and manufacture of overmold products.
insert molding in China is generally much more affordable than in the West (about 50% lower in China, 30% lower in Taiwan) But of course, the whole process has to be carefully monitored to avoid disappointments.

we will devise the appropriate insert mold/mould making strategy for you. We have different ways for a complex small product and a large insert moulding tool. If you need to have real insert molded parts in hand within 2 weeks. Our prototyping team services have very cost-competitive.For the local insert molding or Export

Insert injection molding or injection mould in china

If your company wants lower tooling prices. But still needs the flexibility of insert molding at home we can ship you the moulds. Built according to the specifications of your injection machines. Overall costs (tooling, parts & shipping) are generally about 30% lower. When we do the insert molded parts outside as well.

Let us re-engineer your insert molding parts for lower tooling costs.
In our product design process, we use our principles allow us to make design decisions based on actual manufacturing methods and costs. Which of course leads to more realistic decisions and better cost optimization than applying them when the design is already frozen. Our engineers strictly supervise any redesign effort to make sure that the final part still meets Western aesthetic expectations.

Insert molding material 

Insert molding (or “insert moulding”) is just one of the specialized plastic injection service delivery methods that insert molding and OVERMOLDING are the same as traditional injection molding.
Insert molding is the process of forming or forming plastic parts around other nonplastic parts or inserts
Insert inserts are usually simple metal objects. Such as nuts or stamping parts, and some special items that can be inserted into the complex motor Similarly. Non-metallic materials can also be used to insert molded inserts.

The importance of packaging for plastic products

 In today's world, plastic products have become an integral part of our lives. From household items to industrial tools, plastics are used in almost every sector. However, with the increasing use of plastic products, the importance of packaging has also increased significantly. Packaging plays a crucial role in protecting and preserving plastic products throughout the supply chain. In this blog post, we will discuss the importance of packaging for plastic products.

 

Firstly, packaging helps to protect plastic products from damage during transportation and storage. Plastic products are often fragile and can easily get damaged if not handled carefully. Proper packaging ensures that the products are protected from moisture, dust, and other external factors that can cause damage. Moreover, packaging also helps in reducing the risk of theft and tampering during transportation.

 

Secondly, packaging helps to preserve the quality of plastic products. Plastic products are susceptible to degradation over time due to exposure to light, heat, and moisture. Proper packaging helps to prevent these factors from affecting the products and ensures that they remain in good condition for a longer period. This is particularly important for plastic products that have a longer shelf life, such as medical devices and electronic components.

 

Thirdly, packaging plays a vital role in branding and marketing plastic products. The packaging design and quality can significantly impact the consumer's perception of the product. A well-designed and high-quality packaging can create a positive impression on the consumer and increase brand loyalty. Moreover, packaging can also be used as a tool for differentiation in a highly competitive market.

 

Fourthly, packaging helps to reduce the environmental impact of plastic products. Plastic waste is a significant environmental concern, and proper packaging can help to reduce the amount of plastic waste generated. Packaging that is reusable or recyclable can significantly reduce the environmental impact of plastic products. Moreover, packaging can also be designed to use fewer materials, thereby reducing the overall carbon footprint of the product.

In conclusion, packaging is an essential aspect of plastic products that should not be overlooked. Proper packaging helps to protect and preserve the quality of plastic products, enhances branding and marketing efforts, and reduces the environmental impact of plastic waste. As such, businesses that deal with plastic products should give due consideration to packaging design and quality to ensure that their products are well-protected and marketed effectively.

What is a surface printing?

 

China Plastic injection molding products processing technology

Plastic parts surface printing is a widely used technique in the manufacturing industry that involves applying graphics or text onto the surface of plastic components. This process is commonly used to enhance the aesthetics of products, provide branding or labeling information, and improve overall product visibility.

There are several methods of plastic parts surface printing, each with its own advantages and limitations. One of the most common techniques is pad printing, which involves transferring ink from a silicone pad onto the plastic surface. This method is ideal for printing on irregular or curved surfaces and can produce high-quality, detailed prints.

Another popular method is screen printing, which involves pushing ink through a fine mesh screen onto the plastic surface. Screen printing is suitable for larger print areas and can be used to achieve vibrant colors and intricate designs. However, it may not be ideal for complex shapes or small print areas.

Digital printing is another option for plastic parts surface printing. This technique involves directly printing the desired graphics or text onto the plastic surface using specialized digital printers. Digital printing offers flexibility in terms of design customization and can produce high-resolution prints. However, it may not be as cost-effective for large production runs compared to other methods.

In addition to these techniques, there are also various considerations when it comes to selecting the right ink for plastic parts surface printing. The choice of ink depends on factors such as the type of plastic material, desired print durability, and environmental requirements. Common types of inks used for plastic parts surface printing include solvent-based inks, UV-curable inks, and water-based inks.

When implementing plastic parts surface printing, it is crucial to ensure proper surface preparation to achieve optimal print quality. This typically involves cleaning the plastic surface to remove any contaminants or oils that may interfere with ink adhesion. Additionally, pre-treatment methods such as corona treatment or flame treatment may be necessary to enhance ink adhesion on certain types of plastics.

Plastic parts surface printing offers numerous benefits to manufacturers. It allows for customization and personalization of products, making them stand out in a competitive market. It also provides a cost-effective solution for branding and labeling requirements, eliminating the need for additional labels or stickers. Furthermore, surface printing can enhance product visibility and improve user experience by providing important information or instructions directly on the product.

In conclusion, plastic parts surface printing is a versatile and effective technique for enhancing the appearance and functionality of plastic components. With various printing methods and ink options available, manufacturers have the flexibility to achieve their desired print quality and design customization. By utilizing plastic parts surface printing, businesses can create visually appealing products that leave a lasting impression on consumers.

we are a professional china injection molding factory

We focus on precision mold manufacturing and injection molding manufacturing and also supply your
injection molding after process technology service.

customer quality support

 Overview:

• Parts Design 

• (client may provide completed 3D files)
  The tooling process begins with a completed and checked part design. CNMOULDING can optionally optimize your design before tooling to lower your costs and ensure that your design will work well.
• Parts Prototyping (if necessary)
  If you would like to validate your parts design with a machined piece that you can see and feel, Cnmoulding can use Computer Numerical Control (CNC) techniques to prototype your parts.

• Tool Design

• At this stage the tool is designed, using the information from your completed tools and molds design

• Tool Check and Mold Flow Analysis

• The tool design is validated for correctness.
• Tool Fabrication (including use of Computerized Numerical Control (CNC) and Electrical Discharge Machining (EDM) technologies)
  The tool is precisely fabricated according to the validated design.

• First Shots To Client

• Once the injection molds are made, the first test shot samples will be sent out soon after via an international courier. Once sent, these usually take around 2-5 days to arrive.

• Tool Modifications and Texturing

• At this stage, Cnmoulding completes the tool and makes any required changes to bring the tool into the approved spec. Changes made to bring the tool to spec (specifically excluding design changes, which are always charged) are made free of charge.
  At this stage, texturing also takes place, which is normally the last stage before mass production.

• Mass Production Run or Export

• At this stage, parts are produced and delivered to the customer, or the tool is released for export use.

Technical Topics:

Molding begins with tooling. No matter how good the design, if the tooling is not up to the task, the quality of the parts will suffer.

The Molding Machine

Achieving consistent dimensions and quality requires up-to-date molding machines, operating to specifications, with precise position and pressure control capabilities. The basic construction of a molding machine is fairly straightforward.

Material is fed in through a hopper into a screw and barrel where it is heated to a molten condition. The melt is then injected under high pressure into the mold while the mold is held closed with the high force of a toggle or hydraulic ram. The goal is to melt resin in a very uniform and repeatable fashion, inject it into the mold under very precise and repeatable pressure conditions, and hold the steel temperatures in the entire flow system very stable. After the molten plastic is solidified, the mold is opened and the gear is ejected. It then continues to cool in the open air.

There are many handling and pre-processing requirements for injection molding materials. Engineering polymers quite often must be dried to a specific dew point before use. When parts are made, runners are formed that some shops regrind and put back in the melt. This quite often raises more quality concerns than the slight savings in material expense may justify, and CPIM uses only virgin material.

Injection

The method of injecting the plastic into the mold is very important. In most cases, the plastic should be injected under high pressure very quickly to maintain the good characteristics of the melt completely during the injection. As the mold cavity fills, the injection pressure should be held at the same high value and the speed of injection slowed to maintain that pressure. At the moment when the part is filled, and the molding machine switches over from injection to a pack & hold condition, the plastic melt is held at the same high pressure. This pressure is held for as long as it takes to freeze the gates and achieve the highest weight possible for the molded part. 

Dimensional Inspection in medical Injection Molding

 We produce medical stents for our international clients. However, due to the use of different tools, there have been deviations in the dimensions of the stents, which do not meet the required specifications. As they are current 2.54 mm in diameter and client need to be 2.44 mm in diamete.But it is not the wrong size, but the deviation caused by different measuring tools. After many measurements, it is proved that this position can not be measured with calipers, because the edge of the hole is sharp, and the strength is slightly larger, you can measure the size of the hole, and the best way is to measure it with a gaugeical Injection Molding

Dimensional Inspection in medical Injection Molding

It is crucial to understand that these are special products and therefore require special testing methods to ensure their quality and compliance with international standards.

Dimensional Inspection in medical Injection Molding

The use of different tools has resulted in variations in the dimensions of the medical stents. This deviation from the required specifications is a matter of concern as it can impact the effectiveness and safety of the stents when used in medical procedures. It is imperative that we address this issue promptly and implement measures to rectify the situation.

In order to ensure that the medical stents meet the necessary standards, it is essential to employ special testing methods that are specifically tailored to the unique characteristics of these products. These testing methods should take into consideration the material composition, structural design, and intended application of the stents. By utilizing specialized testing techniques, we can accurately assess the dimensional accuracy, mechanical properties, and biocompatibility of the stents.

Additionally, we must prioritize the implementation of stringent quality control measures throughout the production process to prevent any deviations in the dimensions of the medical stents. This may involve standardizing the use of specific tools, conducting regular inspections, and implementing corrective actions to address any discrepancies.

By addressing the issue of dimension discrepancies in our medical stents and implementing specialized testing methods, we can uphold our commitment to delivering high-quality products that meet the stringent requirements of our international clients. This proactive approach will not only safeguard the reputation of our company but also contribute to advancing healthcare outcomes globally.

In conclusion, the production of medical stents for international clients requires meticulous attention to detail and adherence to specialized testing methods. By acknowledging the impact of tool variations on dimensional accuracy and taking proactive measures to address this issue, we can ensure that our medical stents meet international quality standards and deliver optimal performance in clinical applications.