For those of you who do not have scales here is an easy way to find mold weight.
Calculation For Metric Units (cm)
Measure overall dimensions of the mold.
Refer to above image of mold for length, width & height.
For example:
If Length=80cm Width=90cm Height=45cm
and Weight(kgs)= Length*Width*Height*DensityOfSteel where density is 7.9 grams/cm^3 for tool steel (P20,H13)
then Weight(kgs)= (80*90*45*7.9)/1000= 2,560 kgs
Calculation For Imperial Units (Inches)
Measure overall dimensions of the mold.
Refer to above image of mold for length, width & height.
For example:
If Length=25 inch Width=35 inch Height=20 inch
and Weight(lbs)= Length*Width*Height*DensityOfSteel where density is 0.28 lbs/inch^3 for tool steel (P20,H13)
then Weight(kgs)= (25*35*20*0.28)= 4,900 lbs
All calculations & technical data are for comparison purposes only and are NOT for design or safe working practices. It is derived from sources that we believe to be accurate, but can NOT guarantee its validity. Your specific application should NOT be undertaken without independent evaluation for accuracy.
Bring Your Custom plastic injection mold/molding Project to The JW industry ,we have access to resources that help reduce production costs even further. We proudly offer a total concept solution from design and tooling to material selection, production, and fulfillment .Contact us today to request a free quote and find out how our industry experience and expertise will benefit you with your next project.
2019年4月29日星期一
2019年4月16日星期二
Tips for achieving tight tolerances in injection molding
When it comes to designing and launching a new product or component, there are three things design engineers can always count on:
In order to ensure those tolerances are met, it’s crucial that you get control of them early on in the design phase, and to help you do that – as well as take some pressure off designers – here are some tips for achieving tight tolerances in injection molding.
It Starts with Design
Identifying tight tolerances early in the design phase is key, because design engineers must factor in requirements for part geometry, overall size, and wall thickness – all of which have an influence on tolerance control.
If your design has thick walls, for example, they may have differential shrink rates within the thick sections, making it difficult to hold tight tolerances since the variable shrink can “move“ within the section. Likewise, when it comes to part size, the larger the dimension; the harder it is to hold tight tolerances. A larger dimension also equates to larger shrinkage, which makes it more challenging to maintain and control it.
Pay Attention to Complexity
Another major factor in the design phase is the complexity of the part or product. When done right, that complex design can help aid in the control of tight tolerances. However, common issues with complex designs include shrinking and warping. If the part has too much shrinkage or warpage, the molding process may not be repeatable. That's why it’s absolutely essential for the product design and manufacturing teams to be on the same page.
Also driving the success of managing tight tolerances is the ability to fill cavities quickly, maintain proper cooling temperature, and manage the overall cooling process – which all revolve around tooling design and material flow. Moldflow analysis is critical here, as it can accurately predict mold heating and cooling, as well as shrinkage and warpage. By taking this Design for Manufacturability (DfM) approach, designers can do what’s needed for optimal
control.
Environment Impacts Tolerance
When designing your part or product, it’s critical that your designers have a clear understanding of the environment where the part or product will be used.
Why is this so important? Because the environment influences the behavior of plastic, which in turn, affects tolerance. To better illustrate, consider that plastics typically have large thermal expansion coefficients. That means parts may have to be measured at a consistent temperature to ensure accuracy in determining the part’s ability to maintain a tight tolerance.
For example, if the part or product will be exposed to temperature extremes during normal operation, it will expand and contract. Knowing this beforehand might mean exploring alternative options to a tight-tolerance part or product, and save designers a lot of headaches. This is why it’s so important to consider temperature in the design phase.
While the tips above provide a good start, there’s much more to the success of tight tolerance parts or products than the design alone. While it’s the obvious place to start since design plays a major role in the overall success of a project, it’s always a good idea to get up to speed on other factors involved in working with tight tolerances, ranging from material selection to tooling, and even process design and control.
Jingwei industry has served the electronic industry for years develop and manufacture parts and has a team dedicated to providing you with the most cost effective solutions for design and manufacturing injection molded plastic medical parts . visit us at :jweimolding.com Or contact us via info@jweimolding.com for your project.
- The design is the driving factor behind the success of the product or part and its performance
- If something goes wrong, the design should be the first place you look
- The importance of design is magnified considerably with tight tolerances
In order to ensure those tolerances are met, it’s crucial that you get control of them early on in the design phase, and to help you do that – as well as take some pressure off designers – here are some tips for achieving tight tolerances in injection molding.
It Starts with Design
Identifying tight tolerances early in the design phase is key, because design engineers must factor in requirements for part geometry, overall size, and wall thickness – all of which have an influence on tolerance control.
If your design has thick walls, for example, they may have differential shrink rates within the thick sections, making it difficult to hold tight tolerances since the variable shrink can “move“ within the section. Likewise, when it comes to part size, the larger the dimension; the harder it is to hold tight tolerances. A larger dimension also equates to larger shrinkage, which makes it more challenging to maintain and control it.
Pay Attention to Complexity
Another major factor in the design phase is the complexity of the part or product. When done right, that complex design can help aid in the control of tight tolerances. However, common issues with complex designs include shrinking and warping. If the part has too much shrinkage or warpage, the molding process may not be repeatable. That's why it’s absolutely essential for the product design and manufacturing teams to be on the same page.
Also driving the success of managing tight tolerances is the ability to fill cavities quickly, maintain proper cooling temperature, and manage the overall cooling process – which all revolve around tooling design and material flow. Moldflow analysis is critical here, as it can accurately predict mold heating and cooling, as well as shrinkage and warpage. By taking this Design for Manufacturability (DfM) approach, designers can do what’s needed for optimal
control.
Environment Impacts Tolerance
When designing your part or product, it’s critical that your designers have a clear understanding of the environment where the part or product will be used.
Why is this so important? Because the environment influences the behavior of plastic, which in turn, affects tolerance. To better illustrate, consider that plastics typically have large thermal expansion coefficients. That means parts may have to be measured at a consistent temperature to ensure accuracy in determining the part’s ability to maintain a tight tolerance.
For example, if the part or product will be exposed to temperature extremes during normal operation, it will expand and contract. Knowing this beforehand might mean exploring alternative options to a tight-tolerance part or product, and save designers a lot of headaches. This is why it’s so important to consider temperature in the design phase.
While the tips above provide a good start, there’s much more to the success of tight tolerance parts or products than the design alone. While it’s the obvious place to start since design plays a major role in the overall success of a project, it’s always a good idea to get up to speed on other factors involved in working with tight tolerances, ranging from material selection to tooling, and even process design and control.
Jingwei industry has served the electronic industry for years develop and manufacture parts and has a team dedicated to providing you with the most cost effective solutions for design and manufacturing injection molded plastic medical parts . visit us at :jweimolding.com Or contact us via info@jweimolding.com for your project.
2019年4月9日星期二
Introduction to Injection Molding
Injection molding is going be a big part of your journey to market. Regardless of your technical background you at least need to understand injection molding at a basic level.3D printing is the technology used for prototyping plastic parts, injection molding is the technology used for manufacturing.
Basics of Injection Molding
Injection molding is an ancient technology that has been used since the late 1800’s. Injection molding machines incorporate a huge screw to force molten plastic into the mold at high pressure. This screw drive method was invented in 1946 and is still the method used today.An injection mold consists of two halves that are forced together to form a cavity in the shape of the part to be produced. Hot, liquid plastic is then injected at high pressure into this cavity.
The high pressure is needed to ensure that the plastic resin fills in every crook and cranny of the mold cavity.
Once the plastic has had time to cool, the two halves of the mold are pulled apart, and the part is ejected.
Although designing for injection molding can be quite complicated, and the cost of the molds themselves are incredibly expensive, there is one huge reason why injection molding is still used today.
No technology can beat injection molding when it comes to producing millions of identical copies of a part at an incredibly low price.
Cost of Molds
Injection molds are expensive, and you’ll most likely need a few of them, so their total cost can be quite significant. The more parts you need to produce with the mold the more expensive the mold.This is because the mold must be designed to withstand incredibly harsh conditions. Over and over again a mold is subjected to high temperature and high pressure.These two destructive forces act to quickly degrade the molds to the point of not producing parts of sufficient quality.In order to tolerate this harsh environment injection molds are made from hard metals. The hardness of the metal required is typically determined by how many parts you plan to produce with the mold.
For example, a mold designed to produce 10,000 parts can be made of a much softer metal than a mold designed to produce 1 million parts.
Aluminum is a popular choice if you are producing less than 10,000 parts and works well for low volume production. Once you reach higher production volumes you will need to switch to a harder metal such as steel.
The harder the metal, the more difficult it is to make the mold, so the higher the cost. It also takes much longer to produce a mold from a hard steel. This is because molds are created by milling so a hard mold requires even harder milling tools.
Design for Manufacturing
The high cost of the molds is only one of the issues with injection molding. The other downside to injection molding is that it greatly complicates, and restricts the actual design of your plastic pieces.Once you have a perfectly working prototype from a 3D printer, you then have to spend significantly more time and cost making it work for injection molding.
Keep in mind that you should design your plastic parts for injection molding from the beginning. Some requirements of injection molding, such as draft, can be delayed at least until your second prototype.
But other requirements, such as uniform wall thickness and undercuts, need to be implemented from the very start.
Draft
A main issue with injection molding is that your plastic parts have to be removed from the mold. Once the plastic has cooled, the two halves of the mold are opened and the newly formed plastic piece is removed.
For example, any 3D design for injection molding must incorporate draft. Draft simply means adding a slight angle to any surfaces that are parallel to the direction the part is pulled from the mold. In most cases 1 to 2 degrees is sufficient.
Some experts will tell you that you should include draft in your 3D model from the very start.
While I agree that incorporating draft is important to do early in the development process, I’ve found that it creates unnecessary complications with your first few prototypes.
I generally recommend adding draft once you have a high degree of confidence in your prototype. For most products this means adding draft after the first or second prototype version.
Ejector pins
Ejector pins are used to remove the plastic parts from the mold. As the name implies, these are small cylindrical pins which push outwards to eject the part from the mold.
The location of the ejector pins is not trivial so you need to give some thought to their placement. Ideally, you want them to be located where your part is structurally strong to prevent the part from warping on ejection.
Secondly, the ejector pins tend to leave small marks on the product where they make contact. If you look closely at most plastic parts you will be able to see these tiny, circular indentations from the ejection process.
You want to design your product with this in mind. Strive to have these pins make contact with the part in places that are not critical for the appearance of your product. You may even try to hide the ejector pin marks under a label or logo.
Side actions
If you are unable to easily remove your plastic part from a simple two-piece mold you can use something called side actions.
Side actions are parts of the mold that are inserted during molding, then pulled out before the main mold sections are pulled apart. Their direction of movement is perpendicular to the pull director of the two main mold halves.
Try your hardest to avoid needing side actions, since they add considerable cost and complexity to the molds.
One of the main ways to eliminate side actions is by avoiding the design of undercuts. An undercut is a feature that prevents the part from being removed from the mold with a single pull.
Many times placing a slot underneath the feature will allow the use of a single pull mold instead of requiring side actions.
Uniform wall thickness
One aspect of injection molding that has a huge impact on your product design is the requirement for uniform wall thickness.
After injecting plastic into the mold it is essential that the plastic cools at a uniform rate. If cooling isn’t uniform the part may warp.
Therefore, when designing products for injection molding it’s key to use ribs instead of thicker sections. Designing a part that keeps a uniform wall thickness definitely takes some experience to do correctly.
Two of the most common errors made by 3D designers who don’t understand injection molding are using non-uniform wall thicknesses and requiring the use of side actions.
So make sure whoever does your 3D design knows not to make these rookie mistakes.
Radius/chamfer corners
Perfect corners and edges are not practical to achieve with injection molding. The hot resin simply can’t be forced with enough pressure into the mold to perfectly fill sharp edges. At least, not reliably over large production volumes.
Therefore, all edges and corners should be either rounded or chamfered to allow the resin to fill them more uniformly and consistently.
Cold runners versus Hot runners
Runners is the term used for the channels incorporated into a mold for the hot resin to travel through to reach each cavity.
Larger runners allow the resin to flow more easily and at lower pressures. However, large channels require more time to cool and create more scrap, both of which impact the part cost.
Smaller runners, on the other hand, minimize cooling time, scrap, and ultimately part cost. The downside to small runners is the higher pressure required to force the hot resin to flow through them.
A solution that facilitates the use of small runners while also minimizing the required pressure is to use what are known as hot runners.
Small heating elements are incorporated into the mold near the runners so as to keep the resin more molten allowing it to flow more easily at lower pressure.
Nothing is ever free though, and the downside of hot runners is the additional mold complexity which always translates into additional costs.
In most cases, at least initially, you are best off using only runners without heating elements which are referred to as cold runners. Remember, always start with the simplest, lowest cost solution.
Small heating elements are incorporated into the mold near the runners so as to keep the resin more molten allowing it to flow more easily at lower pressure.
Nothing is ever free though, and the downside of hot runners is the additional mold complexity which always translates into additional costs.
In most cases, at least initially, you are best off using only runners without heating elements which are referred to as cold runners. Remember, always start with the simplest, lowest cost solution.
Single-cavity / Multi-cavity
You can eventually decrease your molding time by using multiple cavity molds. This serves to increase your production speed and reduce your manufacturing part cost.Multiple cavity molds allow you to produce multiple copies of your part with a single injection of plastic. But don’t jump into multiple cavity molds until you have worked through any tweaks or changes to your initial molds. It is wise to run at least several thousand units before upgrading to multiple cavity molds.
Entrepreneurs with a limited budget will want to maximize the use of single cavity molds unless you have a manufacturer financing your mold costs.
Family molds
In most situations, you will need a separate mold for each custom plastic piece required for your product. At a minimum you’ll need at least two pieces: a topside and a bottom side.But many, if not most, products require more than just two pieces of plastic. Molds are very expensive so the cost to purchase multiple molds is a huge financial obstacle.
You should always strive to design your product to minimize the number of unique custom plastic pieces required.
Another option to reduce the number of molds needed is through the use of a special type of multi-cavity mold called a family mold. A family mold allows you to consolidate multiple molds all into a single mold.
Whereas a typical multi-cavity mold creates multiple copies of the same part, a family mold creates different parts at one time.
Sounds great doesn’t it? Unfortunately, nothing is ever easy and every solution has tradeoffs. The main issue with family molds is they require each part to be pretty much the exact same size.
Otherwise, one part will fill up with resin before the other cavities. A family mold must be designed so all of the cavities fill up with resin at nearly the same rate.
That obviously limits their usefulness since it’s unlikely that all of the pieces needed for your product will be the same size.
Material selection
There is an incredible variety of plastic resins at your disposal each with its own characteristics. Two of the most commonly used resins for hardware products are Polycarbonate (PC) and acrylonitrile butadiene styrene(ABS).Polycarbonate has a much higher impact strength and has a much higher-quality appearance compared to ABS. However, PC is of course more expensive than ABS.
Polycarbonate is the most popular plastic used in higher end hardware products because of its higher impact strength and its better aesthetics.
If appearance is critical for your product then PC is most likely the way to go. If your product is low-cost then ABS may be the best choice.
Bring Your Custom plastic injection mold/molding Project to The JW industry ,we have access to resources that help reduce production costs even further. We proudly offer a total concept solution from design and tooling to material selection, production, and fulfillment .Contact us today to request a free quote and find out how our industry experience and expertise will benefit you with your next project.
2019年4月4日星期四
15 Terms About Plastic Injection Molding Industry You Should Know
Today,We put together a list of the 15 more commonly used terms to know when discussing plastic injection molding, mold parts, machinery, materials, and problems. We hope you find this to be a useful resource.
Injection Molding Terms:
Mold:
A hollow form often made from stainless steel that plastic is injected or inserted into to manufacture a plastic part. Molds can be expensive to design and manufacture because of this they are typically only used in mass production. As one of the most significant production investments, it is critical that the molds are made with a great deal of accuracy. Tight-tolerance, precision molds that are made from the best steel available should last for years to come.
Resin:
Resin is the raw material used to create the finished part in the plastic injection molding process. With hundreds of commodity and engineering resins available on today’s market, the material selection process for plastic injection molding may seem daunting at first, so research your options carefully, and consult with an experienced plastic injection molder to help determine the ideal choice.
Mold Cavity:
The hole in the mold that is in the shape of the desired part, this is where the plastic resin is injected into to make the part. Fewer cavities in a mold require less tooling work, time and ultimately less cost. A reputable, experienced molder will be able to maximize cavitation in the mold to maintain the highest level of productivity. In general, most molders recommend creating one mold per part versus creating a family mold. Family molds are created with
various cavities for different parts. They tend to produce inferior products and have more downtime due to maintenance issues.
Colorant:
A pigment system, usually in pelletized form, or liquid, which is mixed with resin to produce the desired color. To pinpoint the desired color for each plastic product or part, a color matching process must be completed, which allows engineers to develop a specific color concentrate for a particular application. Typically, a chip, plaque, or Pantone number provides an approximate idea of the desired hue, and information about the specific polymer being used helps to determine the formulation for the color concentrate.
Wall Thickness:
Of all the various design aspects, wall thickness has the most significant impact on the cost, production speed, and final quality of a part. Wall thicknesses are not subject to any restrictions, but generally, the goal is to create the thinnest wall possible while taking into account the part’s structural requirements and overall size and geometry. The flow behavior and material qualities of the resin should also be considered. Uniform wall thickness also allows for the most efficient, uniform flow of resin through a tool for ideal processing. Variations in wall thickness cause molten polymers to take preferential flows, leading to air trapping, unbalanced filling, and weld lines.
Hopper and Barrel:
The hopper stores the plastic to be used in the injection molding process. For materials such as Nylon, ABS, and PET, a dryer unit may be added to dry the plastic for processing and to keep any external moisture away from the material. The hopper may also contain small magnets to prevent any harmful metallic particles from entering the machine. The plastic that is placed in the hopper is usually in some type of granular form. The plastic material is then melted using heater bands and is then injected through the nozzle into a mold cavity. The pellets are fed from the hopper to the barrel where the material is then melted in a controlled fashion and injected into the mold in the machine.
Flash and Burrs:
Sometimes known as burrs, flash is the occurrence of thin, wafer-like protrusions on a finished part caused when melted resin escapes the mold cavity. Most common along the parting line or an ejector pin, flash can be caused by excessive injection speed or pressure, in which case the fix is a simple reduction.
More often flash is due to poorly designed or severely degraded molds, in which case a redesign or retooling is required. Flash can also be caused by too high of a mold temperature and excessive barrel heat.
Runner System:
The channel system that allows the flow of the melted material to fill the part cavities. There are two main categories: hot runner and cold runner systems. Each of these systems has its benefits and limitations which make them better suited for specific applications. Understanding the differences between these technologies can help you have a more productive and informed discussion with your plastic injection specialist to determine the most feasible option for your unique application.
Hydraulic Process:
Hydraulic is the predominant type of process used in plastic injection molding. These types of machines employ hydraulic cylinders to clamp together two halves of a mold at high pressure. Plastic substrate pellets are then melted, and the liquid is injected into the mold cavity. Once the plastic has cooled and hardened, the mold halves are separated, the part is extracted, and the process is repeated. The hydraulic process uses a hydraulic press which is not as precise as electric presses.
Electric Process:
All-electric presses were introduced in 1983. The newer all-electric press technology is quieter to operate, faster and have higher accuracy. These machines are powered by digitally controlled high-speed servo motors rather than hydraulics, allowing for a faster, repeatable, more precise, and energy-efficient operation. Electric machine operation is highly predictable, so once a desirable injection process has been reached, it can be replicated very consistently,
resulting in higher quality parts. The machinery required for the all-electric process is more expensive than the hydraulic process.
Hybrid Process:
Combining the best of both worlds, hybrid injection molding machines have been on the market for a few decades now, and combine the superior clamping force of hydraulic machines with the precision, repeatability, energy savings, and reduced noise of electric machines. This allows for better performance for both thin- and thick-walled parts. These machines have become increasingly popular over the last few years due to their efficiency and ease of use.
End-of-Arm Tooling:
Speed and efficiency in plastic injection molding equate to cost savings. So, it is no surprise that robots play a significant role in improving the manufacturing process. From simple sprue pickers to complex automated End-of-Arm Tooling (EOAT), the industry is taking advantage of this technology. The EOAT is often assembled along with the electronics, pneumatics, and sensors needed to meet the specific processing requirements of the job.
Tonnage:
Presses are rated, or classified, based on tonnage, which indicates how much clamping pressure a particular machine can offer. Press tonnage, or force, can range from less than 5 tons to over 4,000 tons. The higher a machines tonnage is rated, the larger it is. Pressure keeps a mold closed during the injection process; too little can compromise quality and result in flashing — the appearance of excess material on the part edge. To determine the appropriate size
press for your application, consider the following key variables such as material choice, size of the part and press rating.
Bring Your Custom plastic injection mold/molding Project to The JW industry ,we have access to resources that help reduce production costs even further. We proudly offer a total concept solution from design and tooling to material selection, production, and fulfillment .Contact us today to request a free quote and find out how our industry experience and expertise will benefit you with your next project.
Injection Molding Terms:
Mold:
A hollow form often made from stainless steel that plastic is injected or inserted into to manufacture a plastic part. Molds can be expensive to design and manufacture because of this they are typically only used in mass production. As one of the most significant production investments, it is critical that the molds are made with a great deal of accuracy. Tight-tolerance, precision molds that are made from the best steel available should last for years to come.
Resin:
Resin is the raw material used to create the finished part in the plastic injection molding process. With hundreds of commodity and engineering resins available on today’s market, the material selection process for plastic injection molding may seem daunting at first, so research your options carefully, and consult with an experienced plastic injection molder to help determine the ideal choice.
Mold Cavity:
The hole in the mold that is in the shape of the desired part, this is where the plastic resin is injected into to make the part. Fewer cavities in a mold require less tooling work, time and ultimately less cost. A reputable, experienced molder will be able to maximize cavitation in the mold to maintain the highest level of productivity. In general, most molders recommend creating one mold per part versus creating a family mold. Family molds are created with
various cavities for different parts. They tend to produce inferior products and have more downtime due to maintenance issues.
Colorant:
A pigment system, usually in pelletized form, or liquid, which is mixed with resin to produce the desired color. To pinpoint the desired color for each plastic product or part, a color matching process must be completed, which allows engineers to develop a specific color concentrate for a particular application. Typically, a chip, plaque, or Pantone number provides an approximate idea of the desired hue, and information about the specific polymer being used helps to determine the formulation for the color concentrate.
Wall Thickness:
Of all the various design aspects, wall thickness has the most significant impact on the cost, production speed, and final quality of a part. Wall thicknesses are not subject to any restrictions, but generally, the goal is to create the thinnest wall possible while taking into account the part’s structural requirements and overall size and geometry. The flow behavior and material qualities of the resin should also be considered. Uniform wall thickness also allows for the most efficient, uniform flow of resin through a tool for ideal processing. Variations in wall thickness cause molten polymers to take preferential flows, leading to air trapping, unbalanced filling, and weld lines.
Hopper and Barrel:
The hopper stores the plastic to be used in the injection molding process. For materials such as Nylon, ABS, and PET, a dryer unit may be added to dry the plastic for processing and to keep any external moisture away from the material. The hopper may also contain small magnets to prevent any harmful metallic particles from entering the machine. The plastic that is placed in the hopper is usually in some type of granular form. The plastic material is then melted using heater bands and is then injected through the nozzle into a mold cavity. The pellets are fed from the hopper to the barrel where the material is then melted in a controlled fashion and injected into the mold in the machine.
Flash and Burrs:
Sometimes known as burrs, flash is the occurrence of thin, wafer-like protrusions on a finished part caused when melted resin escapes the mold cavity. Most common along the parting line or an ejector pin, flash can be caused by excessive injection speed or pressure, in which case the fix is a simple reduction.
More often flash is due to poorly designed or severely degraded molds, in which case a redesign or retooling is required. Flash can also be caused by too high of a mold temperature and excessive barrel heat.
Runner System:
The channel system that allows the flow of the melted material to fill the part cavities. There are two main categories: hot runner and cold runner systems. Each of these systems has its benefits and limitations which make them better suited for specific applications. Understanding the differences between these technologies can help you have a more productive and informed discussion with your plastic injection specialist to determine the most feasible option for your unique application.
Hydraulic Process:
Hydraulic is the predominant type of process used in plastic injection molding. These types of machines employ hydraulic cylinders to clamp together two halves of a mold at high pressure. Plastic substrate pellets are then melted, and the liquid is injected into the mold cavity. Once the plastic has cooled and hardened, the mold halves are separated, the part is extracted, and the process is repeated. The hydraulic process uses a hydraulic press which is not as precise as electric presses.
Electric Process:
All-electric presses were introduced in 1983. The newer all-electric press technology is quieter to operate, faster and have higher accuracy. These machines are powered by digitally controlled high-speed servo motors rather than hydraulics, allowing for a faster, repeatable, more precise, and energy-efficient operation. Electric machine operation is highly predictable, so once a desirable injection process has been reached, it can be replicated very consistently,
resulting in higher quality parts. The machinery required for the all-electric process is more expensive than the hydraulic process.
Hybrid Process:
Combining the best of both worlds, hybrid injection molding machines have been on the market for a few decades now, and combine the superior clamping force of hydraulic machines with the precision, repeatability, energy savings, and reduced noise of electric machines. This allows for better performance for both thin- and thick-walled parts. These machines have become increasingly popular over the last few years due to their efficiency and ease of use.
End-of-Arm Tooling:
Speed and efficiency in plastic injection molding equate to cost savings. So, it is no surprise that robots play a significant role in improving the manufacturing process. From simple sprue pickers to complex automated End-of-Arm Tooling (EOAT), the industry is taking advantage of this technology. The EOAT is often assembled along with the electronics, pneumatics, and sensors needed to meet the specific processing requirements of the job.
Tonnage:
Presses are rated, or classified, based on tonnage, which indicates how much clamping pressure a particular machine can offer. Press tonnage, or force, can range from less than 5 tons to over 4,000 tons. The higher a machines tonnage is rated, the larger it is. Pressure keeps a mold closed during the injection process; too little can compromise quality and result in flashing — the appearance of excess material on the part edge. To determine the appropriate size
press for your application, consider the following key variables such as material choice, size of the part and press rating.
Bring Your Custom plastic injection mold/molding Project to The JW industry ,we have access to resources that help reduce production costs even further. We proudly offer a total concept solution from design and tooling to material selection, production, and fulfillment .Contact us today to request a free quote and find out how our industry experience and expertise will benefit you with your next project.
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