Injection molding is the most commonly used manufacturing process for the fabrication of plastic parts. A wide variety of products are manufactured using injection molding, which vary greatly in their size, complexity, and application. The injection molding process requires the use of an injection molding machine, raw plastic material, and a mold. The plastic is melted in the injection molding machine and then injected into the mold, where it cools and solidifies into the final part.Plastic injection molding services are manufacturing in this following process nowadays.
Injection molding is used to produce thin-walled plastic parts for a wide variety of applications, one of the most common being plastic housings. Plastic housing is a thin-walled enclosure, often requiring many ribs and bosses on the interior. These housings are used in a variety of products including household appliances, consumer electronics, power tools, and as automotive dashboards. Other common thin-walled products include different types of open containers, such as buckets. Injection molding is also used to produce several everyday items such as toothbrushes or small plastic toys. Many medical devices, including valves and syringes, are manufactured using injection molding as well.
The process cycle for injection molding is very short, typically between 2 seconds and 2 minutes, and consists of the following four stages:(1)Clamping (2)Injection (3)Cooling (4)Ejection.
After the injection molding cycle, some post processing is typically required. During cooling, the material in the channels of the mold will solidify attached to the part. This excess material, along with any flash that has occurred, must be trimmed from the part, typically by using cutters. For some types of material, such as thermoplastics, the scrap material that results from this trimming can be recycled by being placed into a plastic grinder, also called regrind machines or granulators, which regrinds the scrap material into pellets. Due to some degradation of the material properties, the regrind must be mixed with raw material in the proper regrind ratio to be reused in the injection molding process.
Injection molding machines have many components and are available in different configurations, including a horizontal configuration and a vertical configuration. However, regardless of their design, all injection molding machines utilize a power source, injection unit, mold assembly, and clamping unit to perform the four stages of the process cycle.
The injection molding process uses molds, typically made of steel or aluminum, as the custom tooling. The mold has many components, but can be split into two halves.The two main components of the mold are the mold core and the mold cavity. When the mold is closed, the space between the mold core and the mold cavity forms the part cavity, that will be filled with molten plastic to create the desired part.
There are many types of materials that may be used in the injection molding process. Most polymers may be used, including all thermoplastics, some thermosets, and some elastomers. There are various types of materials which are used in injection molding.They are such as Acetal ,Acrylic ,Acrylonitrile,Cellulose Acetate,Polyamide 6 (Nylon),Polyamide 6/6 (Nylon),Polycarbonate,Polyester, Polyether Sulphone,Polyetherether ketone,Polyetherimide,Polyethylene, Polyethylene, Polyphenylene oxide,Polyphenylene Sulphide,Polypropylene,Polystyrene,Polystyrene, Polyvinyl Chloride and so on…