The process of manufacturing plastic components varies according to the type of part being made. Most parts of this sort are made by a technique known as plastic injection molding. Quality production depends on understanding this process and how it can be adjusted to create components which possess the desired features for their application.
Some examples of products made using the molding technique include electronics, toys, bottles, and automotive parts. Manufacturers appreciate the high precision, low labor expenses, efficient use of materials, versatility in the plastics which can be used, and the ability to produce a high volume of parts at once.
Plastic polymers suitable for molding, mostly fall into one of the following groups; thermosets, elastomers, and thermoplastics. The chemical composition of each polymer blend has different properties which give the manufacturer a large selection. Polymer types are matched to the strength required and intended use of the product.
The basic equipment required for this process are an injection molding machine, or press, and the molds. The press is made up of a hopper, plunger, and heating unit, they are rated according to the tons of clamping force they can exert, which is what's needed to keep the molds intact during production. Molds are the hollow templates used to form the shapes being made, and they are typically made out of numerous types of metal.
The process begins when solid plastic is fed into the hopper of the press and moved along by the action of the plunger to the heating unit where it will be melted. The liquid is then injected through a nozzle into the mold, where the setting takes place under a steady pressure and temperature before the pieces are cooled and ejected. Designing molds in a way which reduces stress on the parts being made is very important when it comes to minimizing product defects.
The molten polymers enter the molds through an opening known as a gate. Gates vary in size, style, and placement, generally the size and type of gate needs to be matched with the item being produced. When pouring molds, it's also important to aim to make the walls of the objects as thin as possible, as to use materials efficiently and shorten the cooling cycle.
If something other than a smooth surface is desired for a molded object, a process known as texturing is implemented. Patterns are added to the surface of the part to give it a particular appearance. Besides serving an aesthetic purpose, this technique can also be useful in a practical sense for disguising minor flaws and to minimize the effects of friction over time.
Some examples of products made using the molding technique include electronics, toys, bottles, and automotive parts. Manufacturers appreciate the high precision, low labor expenses, efficient use of materials, versatility in the plastics which can be used, and the ability to produce a high volume of parts at once.
Plastic polymers suitable for molding, mostly fall into one of the following groups; thermosets, elastomers, and thermoplastics. The chemical composition of each polymer blend has different properties which give the manufacturer a large selection. Polymer types are matched to the strength required and intended use of the product.
The basic equipment required for this process are an injection molding machine, or press, and the molds. The press is made up of a hopper, plunger, and heating unit, they are rated according to the tons of clamping force they can exert, which is what's needed to keep the molds intact during production. Molds are the hollow templates used to form the shapes being made, and they are typically made out of numerous types of metal.
The process begins when solid plastic is fed into the hopper of the press and moved along by the action of the plunger to the heating unit where it will be melted. The liquid is then injected through a nozzle into the mold, where the setting takes place under a steady pressure and temperature before the pieces are cooled and ejected. Designing molds in a way which reduces stress on the parts being made is very important when it comes to minimizing product defects.
The molten polymers enter the molds through an opening known as a gate. Gates vary in size, style, and placement, generally the size and type of gate needs to be matched with the item being produced. When pouring molds, it's also important to aim to make the walls of the objects as thin as possible, as to use materials efficiently and shorten the cooling cycle.
If something other than a smooth surface is desired for a molded object, a process known as texturing is implemented. Patterns are added to the surface of the part to give it a particular appearance. Besides serving an aesthetic purpose, this technique can also be useful in a practical sense for disguising minor flaws and to minimize the effects of friction over time.
About the Author:
Genevive B. Mata has taught plastics molding techniques for over 15 years. He specializes in injection molding and thermoforming. If you are interested in learning more about plastic injection molding services then he recommends you visit his friends at PTM: Custom Plastics Injection Molding Company.
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