by Renaud Anjoran
We are continuing with our series of articles about a specific process.
Injection molding as a process has been around since the early 1930s, but a lot has changed since those early days.
The injection mold machines have become sophisticated pieces of equipment with closed loop control systems monitoring every aspect of the process you can think of. Polymer development has become a complex science with blends available to cater for virtually every possible product imaginable.
The process of injection molding is composed of 6 steps:
The very basics of a mold machine consist of three elements, the mold, the clamping unit, and the injection unit. The clamping unit is what holds the two halves of the mold together during the injection process.
During the injection stage of the process, the raw plastic (technically known as polymer) is loaded into a hopper which is located at the top of the machine. From there the polymer is fed into the injection cylinder where it is heated until it reaches melting point.
The molten polymer is then pushed up to the end of the injection cylinder by the use of a specially designed rotating screw. Once there is enough molten polymer at the end of the cylinder, the screw forces it into the mold at a controlled speed and pressure.
The dwell time is basically a pause after the mold has been filled but with a bit of extra pressure behind the screw ensuring the mold and all the cavities are completely full.
The injected polymer is then cooled so that it solidifies into the final shape of the mold.
Now it is time to open the mold. The clamping mechanism is released and the machine opens the two halves of the mold.
Once the mold is open, the molded part can be ejected. This is achieved through a plate moving in from the back of the mold and using dowel pins to push the part out of the mold. This is the last step within the cycle. After this the process starts all over again.
You can have a look at Wikipedia’s drawings and photos. They are much nicer than ours and (I hope) outside of any confidentiality commitment.
There are good reasons why this technology is widely used:
And China is particularly competitive for several reasons:
To be fair, there are also limitations:
Our engineers report back on detailed checklists that are organized in 18 sections:
The objective for the buyer is to have a good idea about the risks associated with engaging a particular manufacturer. Very often, molds need to be custom-made and it represents a substantial investment.
Maybe some readers can share other points to evaluate?