Look around you. There’s a huge chance a lot of the things you see around you are made of plastic. This fact does not even come as a surprise, knowing that plastic can be molded into so many different things. With the right materials and the expertise of a trusted plastic injection molding service, you can turn that product idea into something real. Why is plastic the top choice when creating a new product? For one thing, plastic is extremely versatile, with a number of different ways to mix and match the base elements with additives to come up with the perfect product. Do you need something durable with a smooth finish? Or would you perhaps prefer something softer, something more manageable? Regardless of what your needs are, there will always be a way to attain the results you want. Production costs are also low when it comes to plastic. They are great electrical insulators, are resistant to corrosion, and when used the right way, can be easily recycled. Without a doubt, plastic is one of the best materials you can use if you’ve come up with a brilliant idea for a product. How Custom Plastic Injection Molding Works Because your product idea would probably work best using plastic as your main material, the next thing you should be looking into is finding out how the entire process works. How can you turn your idea into a real plastic product? That’s what custom injection molding is for. Basically, the plastic material is fed into the part of the machine called a hopper, which then pushes it into the extruder. From here, the material is pushed further into the heating chamber, where the plastic is melted. Now that the plastic is in melted form, it’s time to mold it into the shape of the custom plastic parts you need. The molten plastic is pushed into a closed cold mold using extreme amounts of pressure. Without the right pressure, the mold will not be filled, and the plastic will not take the shape you want. Basically, it’s the mold that serves as a guide or pattern. It forms the shape of the plastic. Once the plastic has cooled and solidified, it is ejected from the chamber. And from here, you can see that the finished product now takes the shape it was meant to take. From here, some finishing work may still be done. Some plastic parts require painting, for example, while some may need a finer finish, which means that any excess plastic parts may have to be shaved off.
With the right kind of manufacturer and the right idea, you can create something wonderful and change the course of mankind.
Jingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist. To learn more about our manufacturing capabilities and discover what makes us different, please visit our website: :jweimolding.com . If you're ready to jump into your next project with us, request a quote . No matter your need, contact us today so we can help your business face all of the changes and challenges of today's competitive marketplace.
One of the major innovations of the past century has been the introduction and wide adoption of plastics for many day-to-day applications that previously relied on traditional materials like metal, glass, or cotton. Plastics have revolutionized many industries for a number of different reasons to include the fact that they resist environmental degradation over time, are generally safe for human beings, are economical and widely available, and are produced with a wide variety of material properties that allow adaptation to many different applications. Here is our list of the top 11 plastics the modern world simply cannot do without:
Polyethylene terephthalate (PETE or PET):
PET is the most widely produced plastic in the world. It is used predominantly as a fiber (known by the trade name “polyester”) and for bottling or packaging. For example, PET is the plastic used for bottled water and is highly recyclable.
Three words or short phrases to describe the major benefits of Polyethylene relative to other plastics and materials would be:
Wide applications as a fiber (“polyester”) Extremely effective moisture barrier Shatterproof
2,Acetal (Polyoxymethylene, POM):
Acetal is a very high tensile strength plastic with significant creep resistant properties that bridge the material properties gap between most plastics and metals. It is known for high resistance to heat, abrasion, water, and chemical compounds. Additionally, Acetal has a particularly low coefficient of friction which combined with its other characteristics makes it very useful for applications that utilize gears.
Two words or short phrases to describe the major benefits of Acrylic relative to other plastics and materials would be:
Transparent Scratch Resistant 3,Polyvinyl Chloride (PVC):
Polyvinyl Chloride is perhaps most well known for its use in residential and commercial property construction applications. Different types of PVC are used for plumbing, insulation of electrical wires, and “vinyl” siding. In the construction business PVC pipe is often referred to by the term “schedule 40” which indicates the thickness of the pipe relative to its length.
Three words or short phrases to describe the major benefits of PVC relative to other plastics and materials would be:
Brittle Rigid (although different PVC variants are actually designed to be very flexible) Strong 4,Polypropylene (PP):
Polypropylene is used in a variety of applications to include packaging for consumer products, plastic parts for the automotive industry, special devices like living hinges, and textiles. It is semi-transparent, has a low-friction surface, doesn’t react well with liquids, is easily repaired from damage and has good electrical resistance (i.e. it is a good electrical insulator). Perhaps most importantly, polypropylene is adaptable to a variety of manufacturing techniques which makes it one of the most commonly produced and highly demanded plastics on the market.
Two short phrases to describe the major benefits of Polypropylene relative to other plastics and materials would be:
Unique Use For Living Hinges Simple To Manufacture 5,Polystyrene (PS):
Polystyrene is used widely in packaging under the trade name “styrofoam.” It is also available as a naturally transparent solid commonly used for consumer products like soft drink lids or medical devices like test tubes or petri dishes.
One short phrase to describe the major benefits of Polystyrene relative to other plastics and materials would be:
Foam Applications 6,Polyethylene (PE):
There are a number of different variants of polyethylene. Low and high density polyethylene (LDPE and HDPE respectively) are the two most common and the material properties vary across the different variants.
LDPE: LDPE is the plastic used for plastic bags in grocery stores. It has high ductility but low tensile strength. HDPE: A stiff plastic used for more robust plastic packaging like laundry detergent containers as well as for construction applications or trash bins. UHMW: Extremely strong plastic that can rival or even exceed steel in strength and is used is for applications like medical devices (e.g. artificial hips). 7,Polycarbonate (PC):
Polycarbonate is a transparent material known for its particularly high impact strength relative to other plastics. It is used in greenhouses where high transmissivity and high strength are both required or in riot gear for police.
Two words or short phrases to describe the major benefits of Polycarbonate relative to other plastics and materials would be:
Transparent High Strength 8,Acrylic (PMMA):
Acrylic is best known for its use in optical devices. It is extremely transparent, scratch resistant, and much less susceptible to damaging human skin or eye tissue if it fails (e.g. shatters) in close proximity to sensitive tissue.
Two words or short phrases to describe the major benefits of Acrylic relative to other plastics and materials would be:
Transparent Scratch Resistant 9,ABS (Acrylonitrile Butadiene Styrene):
ABS has a strong resistance to corrosive chemicals and physical impacts. It is very easy to machine, is readily available and has a low melting temperature making it particularly simple to use in injection molding manufacturing processes or 3D printing.
Four short phrases to describe the major benefits of ABS relative to other plastics and materials would be:
Impact Resistant Readily Available Simple To Manufacture 10,Acetal (Polyoxymethylene, POM):
Acetal is a very high tensile strength plastic with significant creep resistant properties that bridge the material properties gap between most plastics and metals. It is known for high resistance to heat, abrasion, water, and chemical compounds. Additionally, Acetal has a particularly low coefficient of friction which combined with its other characteristics makes it very useful for applications that utilize gears.
Two short phrases to describe the major benefits of Nylon relative to other plastics and materials would be:
High Strength Temperature Resistant 11,Polylactic Acid (PLA):
Polylactic Acid is unique in relation to the other plastics on this list in that it is derived from biomass rather than petroleum. Accordingly it biodegrades much quicker than traditional plastic materials.
Two words or short phrases to describe the major benefits of Polylactic Acid relative to other plastics and materials would be:
Biodegradable
DIY 3D Printing (compare PLA to ABS)
No matter what the application is there are different plastics with the right material properties to suit the requirements.Jingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist. To learn more about our manufacturing capabilities and discover what makes us different, please visit our website: :jweimolding.com . If you're ready to jump into your next project with us, request a quote . No matter your need, contact us today so we can help your business face all of the changes and challenges of today's competitive marketplace.
Choosing the appropriate material for plastic injection molding part production is critical. There are approximately 85,000+ thermoplastics available in the marketplace. Within the vast material options available, there are approximately 40 polymer blends or families. A variety of attributes should be considered when making a final resin selection such as:
• Chemical Resistance-Should the strength of the material protect against chemical or solvent reaction? • Tensile Strength-What is the resistance of the material to breaking under tension?
• Durability-What is the material’s ability to withstand pressure, damage or wear? • Flexibility-Can the material bend without breaking? • Temperature Resistance-Will the product be exposed to high or low temperatures? How will it react to other factors or materials in the manufacturing process?
• Aging-Is there a shelf life required for the material? • Impact Resistance-What is the ability of the material to withstand a high force or shock applied to it over a short period of time? • Environment-Will outside factors impact the product such as weather, chemicals, or other conditions? • Overmolding-Working with two independent materials, how and will the two materials interact with each other in the manufacturing process?
• Material Cost-Will you select a premium or equivalent grade material? • Product Availability-What is the lead time (availability) of the material?
Jingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist. To learn more about our manufacturing capabilities and discover what makes us different, please visit our website: :jweimolding.com . If you're ready to jump into your next project with us, request a quote . No matter your need, contact us today so we can help your business face all of the changes and challenges of today's competitive marketplace.
Injection molding is a manufacturing process commonly used for fabricating items from plastic case and toys to automotive body parts, cell phone cases, water bottles, and containers. Essentially many of the plastic parts that we use in every-day life are injection molded. It is a quick process to create a mass amount of identical plastic parts. The flexibility in shape and size achievable by the use of injection molding has consistently widened the boundaries of design in plastics and allowed substantial alternatives of traditional materials due to design freedom and light weighting. How does it work?
An injection machine is made up of three primary components – the feed hopper, the screw and the heated barrel. Plastic granules for the part are fed into the heated barrel by a hopper. Plastic that is placed in the hopper is usually in powder or granular form although some resins, for instance silicone rubber, may be a liquid and might not entail heating. The material is then melted utilizing the frictional action of a reciprocating screw accompanied with heater bands. The molten plastic is then injected through the nozzle and into a mold cavity – it may seem easy, but injection molding is actually a very complex process. While in the mold cavity, the material cools and solidifies to the configuration of the cavity. When the part has hardened, the moveable platen that the mold is mounted opens and the part is ejected using ejector pins.
Injection molding machine sizes can run anywhere from 5 tons of clamping force to over 6000. The higher the tonnage, the larger the machine. In fact, injection molding machines are classified based on tonnage, or more precisely the clamping force or pressure.
For example, a machine that is capable of delivering 80 tons of clamping pressure is rated for 80 tons. This pressure ensures that the mold remains closed during the injection process. Too little or too much pressure can cause part quality issues as well as flashing, where excess material surfaces on the edge of the part. The viscosity of the plastic being used is also impacted by pressure. MFI or Melt Flow Index is a measure of the melt of a thermoplastic polymers ease of flow.
Another factor in sizing the correct machine is shot size and mold dimensions.
The clamping unit’s main function is to close and open the mold as well as ejecting the parts. Two of the most common types of clamps are the toggle clamps and the hydraulic clamps. Toggle clamps are traversed by hydraulic cylinders. These clamps use mechanical connections to generate greater forces than a hydraulic cylinder of the same size that uses a direct connection.
While the fundamentals of injection molding remain somewhat constant, the more technology we introduce into the existing clamp and injection processes the more complex the considerations become when developing a mold or building a machine for injection molding.
Jingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist. To learn more about our manufacturing capabilities and discover what makes us different, please visit our website: :jweimolding.com . If you're ready to jump into your next project with us, request a quote . No matter your need, contact us today so we can help your business face all of the changes and challenges of today's competitive marketplace.
Moisture affects the quality of the molded part in different ways, and the extent is determined by either the specific resin being processed or the purpose of the part. Improper or incomplete drying can create problems, either when the part is being processed or when the product is in use, or sometimes, both.
Drying plastics resin is done to reduce or eliminate problems caused by too much or too little moisture in plastic material as it is being processed. Most processors accept the need to pre-dry plastic resins, particularly hygroscopic resins, but many don’t understand the basics of resin drying.
There are 4 fundamental drying parameters for all polymers: Heat The first fundamental drying parameter is heat. The pellet will not release its moisture if you don’t heat it. Hygroscopic polymers are strongly attracted to water. The water molecules are bound to the polymer chains. Heat weakens the forces bonding the water molecules to the polymer chains, causing the molecules to move powerfully. If the temperature is high enough, the force binding the molecules to the chains are reduced, which allows for free movement of the water molecules to move the drying process along. Dew point The second fundamental drying parameter is dew point. Dew point is the temperature at which the air condenses. When the pellet is surrounded by the low vapor pressure of the dry air, it causes freed moisture molecules to move to the surface of the pellet. Drying time The third fundamental drying parameter is drying time. Plastic pellets do not dry immediately. First, they must be heated to let water molecules move freely, then enough time must pass for the molecules to de-fuse to the hygroscopic pellet surface. Airflow The fourth fundamental drying parameter is airflow, which carries heat or dry heated air to the material in the drying hopper. There must be a low dew point heated air forced over the material in order for the molecules of moisture to be detached from the chains and moved to the pellet surface where the airflow will carry the moisture away. Dry air volume must be sufficient enough to develop and maintain the desired temperature profile in the hopper.
To prevent defects, drying must be done properly in the molding or extrusion process. You can increase and optimize the molding times and extrusion rates by uniform drying to a low, consistent moisture level, maintaining a constant temperature, keeping the drying system in working condition, and using dryers that offer the latest drying technology to avoid temperature or point spikes, or any other issues that could arise.
ingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist. To learn more about our manufacturing capabilities and discover what makes us different, please visit our website: :jweimolding.com . If you're ready to jump into your next project with us, request a quote . No matter your need, contact us today so we can help your business face all of the changes and challenges of today's competitive marketplace.
Mold making is a process of making injection molds that are used to produce hundreds of or thousands precision plastic parts. As one of the most significant production investments, it is critical that the molds are made with a great deal of accuracy. Modern mold making requires extreme precision to ensure that parts can be mass-produced with repeatable accuracy. This perfection is also required in the creation of the tools used to manufacture, hold, or test products during production. Quality precision molds are built to last and represent an essential investment for any company. Variables that can impact the cost of the plastic injection mold include: . Core Metal .Number of Cavities .Mold Base .Core/Cavity Machining .Part Complexity What Has Changed? Plastic injection molding first gained prominence during the 18th and 19th centuries. With the Industrial Revolution at its peak, toolmakers had to do most everything by hand. Forming tools, heat treating, sharpening, machining metal, and drilling out the design by hand required a significant time commitment.
Due to the uniqueness of anything made by human hands, conformity problems often arose, and no two molds were precisely the same.Now, Computer Numerical Controlled (CNC) milling machines offer so many kinds of tools for cutting that the simple term and concept of “mold making” no longer covers the full gamut of the current capabilities. Today’s technology enables the fabrication of items with much more accuracy and range than ever before. The process is more precise than manual machining, and can be repeated in exactly the same manner over and over again. Because of the precision possible with CNC Machining, this process can produce complex shapes that would be almost impossible to achieve with manual machining.
The use of CNC machines not only speeds up the process but also offers a wide degree of flexibility. Computers can often be programmed to work overnight, providing around-the-clock production. Using computer-generated inputs, CNC machining are able to deliver precision, accuracy, and levels of consistency that manual machining could never before offer. Working with Jingwei molding Jingwei molding provides innovative manufacturing solutions that include mold design, mold building, and high-volume parts manufacturing. We are world renowned for the production of injection molded components of the highest quality and precision at highly competitive prices. From concept to completion, we provide all of the necessary resources to promptly and accurately complete your project. We serve industries ranging from consumer products and construction to auto , medical and pharmaceutical, and electronic and other custom plastic parts.
Jingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist. To learn more about our manufacturing capabilities and discover what makes us different, please visit our website: :jweimolding.com . If you're ready to jump into your next project with us, request a quote . No matter your need, contact us today so we can help your business face all of the changes and challenges of today's competitive marketplace.
When making decisions about process optimization, tool engineers and process engineers work together to proactively identify and correct any tooling weaknesses, following these 8 steps:
1. TOOL FUNCTIONALITY EXAMINATION
Every aspect of the tool's mechanical functionality is assessed to make sure everything works as designed, using the material settings provided by the supplier of the material to be molded. 2. SHORT SHOT TESTING
Dynamic pressure loss and, in a multiple-cavity tool, cavity imbalance are determined and documented using sample parts. Also, the rheology curve (or viscosity curve) is established to indicate the best fill rate and pattern.
3. GATE SEAL STUDIES
Both the pressure curve and weight of the sample parts are observed to see if the gates fully seal and at what point sealing occurs. 4. SAMPLE PARTS EVALUATION/DATA RECORDING
All defects are examined and recorded, along with recommendations for any adjustments in the process or the tool in order to correct the defects. Likewise, data is recorded with regard to melt temperature, fill time, tool temperature, coolant flow, cycle time and pressure curves.
5. QUALITY CONTROL
The sample parts go to quality control for examination and documentation of their measurements, shot-to-shot consistencies and overall quality.
6. TOOL ADJUSTMENTS
Based on information gathered during quality control, necessary tool adjustments are made, and new sample parts are made.
7. NEW SAMPLE CREATION/QUALITY CONTROL TESTING
The new sample parts are subjected to the same quality testing and more adjustments are made, if necessary.
8. PROCESS PARAMETER/PERFORMANCE RANGES VERIFICATION
The quality testing and adjustments continue until all process parameters meet their performance ranges. Once verified, the tool is ready for use and the process is deemed optimized.
By leveraging scientific molding, experienced custom injection molding engineers understand each phase of development — from tool design and mold fill analysis to process monitoring and quality control. The result? The most efficient and robust process possible for manufacturing the complex injection molded plastic parts and products you need for complex applications from medical devices, electronic parts to automotive parts and other custom plastic parts.
