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8 Design Rules for Injection Moulded Products

Injection moulding is a versatile process and can be applied to almost any product. Although injection moulding is the industry standard for fabricating parts for products, it is not without its holdups. There are a few basic limitations to be taken into account. Here’s eight rules to follow when designing your product to ensure quality and durability:

Maximum wall thickness. The wall thickness of your part is directly proportionate to both the total materials needed to make the part and the cooling time required. By reducing the maximum thickness of the wall of your part, you reduce both these factors, resulting in lower cycle time, thus lower production costs. If the wall of your part is too thick or is inconsistent, problems can be caused involving sinkage and warpage, resulting in rejects and costly redesigns. Ensure your wall thickness is matched to the capabilities of the machine.
Corners. They can be a problem in a mould and will not always come out flush. It is almost impossible to force plastic into a perfect corner, and the result will look messy and amateurish, not to mention the strength of the part could be compromised. Round all corners where possible to enhance aesthetics and durability.
Applying a draft. A draft is a tiny angle — usually one or two degrees — applied to the mould on the face perpendicular to the parting line. This will allow for easy removal of the piece from the mould. Not including a draft in your design will mean the automatic ejection system of the injection moulding machine will not operate.
Ribs. Ribs are structural elements for your part, used for overall stability control. They are thin wall protrusions that extend perpendicularly from a wall or plane. Adding ribs rather than thicker walls will offer greater structural support.
Bosses. Bosses are hollow, cylindrical protrusions usually included in a design for accepting screws or other mating components of your deign. Ensuring these are secured by either attaching them to a wall or adding ribs will mean the bosses will remain straight and accept the part it was designed for without a problem.
External undercuts. A protrusion or depression in the outside of your mold — the cavity half — can create problems when trying to separate parts from the mold. Adjust your parting line to accommodate this.
Internal undercuts or overcuts. Similar to external undercuts, these protrusions or depressions are on the inside of your mold — on the core half. Adjust your parting line to accommodate this.
Threads. If your mould contains a thread, always arrange it perpendicular to the parting line. This will ensure that the fragile thread is not damaged. It is better, if possible, to not include a thread at all in your design. Simplifying your design will lower the chance of something going wrong.

Injection moulding design ensures a quality product and the countless possibilities far outstrip the limitations. Designing for a quality injection moulded product is the essence of the design process, and these limitations are the guidelines for creating a versatile end product.

 

3 Main Cost Drivers in Injection Moulding

Injection moulding is an efficient and effective way of producing quality plastic goods. Quality is often assured, but as with any production process, there are factors to consider when cost is an issue. It is usually the cheapest way of manufacturing a product, but that doesn’t mean it won’t necessarily be expensive.

The cost of injection moulding may in part be dependant on the quality of the materials used, size and intricacy of the part, but here’s a rundown of the three biggest cost drivers when it comes to injection moulding.

Part design. A good part design will save a lot of money. When designing a part to be injection moulded, may things must be taken into consideration. For maximum efficiency, a part will be designed with consideration for materials, cooling time and the labour needed to create the tool. Bad part design will cost a lot of time and wasted effort. A badly designed part will cause rejects, slower cycle times (including cooling time) and extra labour. The part may not be designed well for tooling — especially if a part is complicated or intricate — and may require extra or special tooling costs. A part may be designed so that it still requires post-moulding work, adding yet more labour. This is not taking into account transport and packing costs; a good design will account for space requirements when in storage and shipment. Good part design reduces the costs of plastic moulding dramatically.
Tooling. The quality of the mould creation will alter the cost of injection moulding to a large extent. A mould’s design limitation is the parting line — the line which divides the two halves of the mould, the core and the cavity. This must be carefully considered when tooling a mould. For instance, a protruding portion of the mould, if the mould is correctly tooled, can be orientated along the parting line. If the mould is incorrectly tooled, however, this will create an undercut or overcut, and the part will snag in the mould. This will require labour to fix and will cost precious time that could be being used to create more parts.
Tool design. The quality of your tool design will impact immediately on both the quality and production cost of your finished part. Nothing accounts for quality, and the reliability of a tool that will deliver what you want every time will outstrip your initial investment in a very short amount of time. For instance, a cheaper injection moulding tool will only save you money in the short term. Long term, it’s lack of reliability and slow running time is likely to become a liability. Investing in a quality tool design specifically matching your needs and requirements will ensure you will have a consistently high-quality end product.

Taking time to consider your needs will bring you a worthwhile return on your investment. By insisting on good part design, tooling and tool design, you are assured a relatively stress-less endeavour when setting out to produce your product.

 

How Does an Injection Moulding Machine Work?

An injection moulding machine is a complex piece of machinery that creates one solid piece by injecting molten materials through a reciprocating screw system into a mould. This machine is made of many components; it is primarily consisted of a hopper, a barrel containing a reciprocating screw, temperature control devices, a clamping unit and the injection mould itself.

The process begins with the creation of a mould. The mould is created by the Toolmakers from the specifications given to them from the designer or engineer via a 3D computer-generated model. The mould is carefully constructed to allow the two halves of the mould — the mould cavity and the mould core — to separate along the parting line. This will allow easy ejection from the injection moulding machine when the part has cooled. If the mould is designed incorrectly the part may catch on the mould, resulting in possible damage.

The specifications and components of the machine must be carefully set up before the process of injection moulding can begin. Temperatures and pressures will be programmed according to the size and shape of the mould and the material that the part is to be made from. Once the machine is set, the cycle will begin and the machine can be left unattended to work its magic.

This is how it works:
Raw material and colour is fed into the barrel of the machine via the hopper. In the barrel the raw materials are subjected to pressure and temperature until they are melted and malleable. The reciprocating screw inside the barrel will turn, injecting a precise amount of the now molten plastic into the injection mould at a set and controlled temperature, pressure and speed. Once the mould is filled with the molten plastic the injection process will shut off. The part is then allowed to cool until it is ready to be taken from the mould. This can take some time depending on the materials, wall thickness, overall size and shape of the part being manufactured. When cool, the mould will open automatically. The mould is inbuilt with an ejecting mechanism which ejects the part in preparation for a new cycle. If a portion of the finished part is still caught in the mould at this point the mould will reopen until the part has been completely ejected. When the part is clear of the machine, the hopper will release more raw material and colour into the barrel and a new cycle will begin. The autonomous nature of the injection moulding machine means it can be left unattended once programmed, and may run continuously throughout day and night.

The basic concept of the plastic moulding machine has been around for over seventy years. Since then the original idea — injecting molten plastic into a mould — has evolved dramatically into an efficient, elegant and versatile tool for creating everyday items.

 

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What Can Injection Moulding Do?

Injection moulding can do almost anything. This technology, created in the 1940s and constantly refined, allows for incredible flexibility in product design and has effectively revolutionised mass production.

Injection moulding is the process of forcing molten materials into a mould or die. The material is then cooled, the finished result taking on the physical characteristics of the mould’s cavity or hollow. Injection moulding is used for almost every plastic product that you will encounter on an everyday basis.Everything from the cap of your soft drink bottle to the dashboard of your car has been created through the injection moulding process. Even the plastic components that make up the computer that you’re using right now have been injection moulded.

There are a variety of materials that are compatible with injection moulding — from plastics to metals; almost anything that can be made malleable. The machine types vary in size, shape and running costs, allowing for a huge range of customisation. As with most items manufactured in mass quantities, plastic or metal products can be made in the same mould time and time again, meaning the cost of creating the mould is spread over the total number of items created. This allows items like coat hangers, toys and DVD cases to be produced for little more than the cost of the materials, whereas limited-run products, such as vinyl toys or custom-created art pieces will cost a lot more per unit.

You will find injection moulded products everywhere. The next time you buy a children’s meal from a fast food restaurant, you will likely find a toy comes with it. The cost of producing that toy will be very small as hundreds of thousands of the exact same toy have been created using the same plastic moulding shape (not to mention the cheaper materials). It may seem incongruous, but artists and designers take advantage of the same technology, using the process to create custom moulds. These one-off products will cost a lot more than the per-unit price of creating, say, one hundred from the same mould.

There are limitations to injection moulding. The nature of the process demands that only one whole, solid piece be created at one time. Designers and manufacturers get around this problem by altering their product design to these limitations. For instance, a toy plastic car will have two moulds for each half of the outside shell and perhaps another mould that will detail the inside, such as seats, dashboard and steering wheel. Injection moulding is so ingrained in our society that the limitations of injection moulding are not even considered limitations. If something cannot be created using injection moulding, there are very little options available, save carving the object by hand (a laborious task if you’re to create thousands of items exactly the same).

Injection moulding is versatile and a very necessary part of modern society. Able to create almost anything – functional or aesthetically pleasing – it broadens the horizons of tradesmen, artists, designers and everyday people. In short, injection moulding can create almost anything.

 

Injection Molding Plastic

Plastics are synthetically produced non-metallic compounds. It can be molded into various forms and toughened for commercial use. Plastic molding products can be seen everywhere. Examples are jars, protecting caps, plastic tubes, grips, toys, bottles, cases, accessories, kitchen implements and a load more.

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Even the keyboard and the mouse that you use are made thru plastic molding. Even the plastic parts of the chair that you are sitting on are created this way.

The basic idea in plastic molding is inserting molten liquid plastic into a prepared formed mold, for instance the mold of a bottle. It is going to be then allowed to cool, then the mold will be removed to bare the plastic bottle.

Plastic molding can also custom-mold a wide variety of plastic products including : garden pots, cupboards, office trays and boxes, barriers, barricades and traffic signage and displays for product and selling promotions.

If you are planning to go into plastic molding business, you should first know the different processes. Choose from a plastic molding process that fits your position, your expertise, and your resources. Here are basic definitions of various techniques of plastic molding.

The Plastic Molding Processes :

1. Injection Molding

In Injection Molding, liquified plastic is forced into a mold hole. Once cooled, the mold can be removed. This plastic molding process is sometimes used in mass-production or prototyping of a product. Injection molding machines were made in the 1930’s. These can be employed to mass produce toys, kitchen implements, bottle caps, and cell phonephone stands to name a couple.

two. Blow Molding

Blow molding is like injection molding except that hot liquid plastic pours out of a barrel vertically in a molten tube. The mold closes on it and forces it outward to comply with the inside shape of the mold. When it is cooled, the hollow part is made. Examples of blow molding products are bottles, tubes and boxes.

Equipments required in setting-up a blow molding business are comparatively higher than injection molding.

3. Compression Molding

In this kind of plastic molding, a slug of hard plastic is pressed between 2 heated mold halves. Compression molding usually uses vertical presses rather than the horizontal presses used for injection and blow molding. The parts formed are then air-cooled. Costs of equipments used for compression molding are moderate.

four. Film Insert Molding

This plastic molding technique imbeds an image beneath the outside of a molded part. A material like film or fabric is inserted into a mold. Plastic is then injected.

5. Gas Assist Molding

Also called gas injection molding is used to create plastic parts with hollow interiors. Partial shot of plastic is then followed by hi-pressure gas to fill the mold cavity with plastic.

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Plastic Extrusion Molding

Plastics extrusion is a high volume manufacturing process in which raw plastic material is melted and formed into a continuous profile. Extrusion produces items such as pipe/tubing, weather stripping, window frames, plastic sheeting, adhesive tape and wire insulation. Thermoplastic materials are fed from a hopper into the heated barrel of an extruder. A rotating helical screw inside the barrel pushes the plastic through the barrel toward the die located at the end of the machine. Molten plastic is then forced through the die opening.  Thus, the process of forming a continuous piece of plastic by forcing it through a shaping orifice with or without the presence of heat is called plastic extrusion molding.

Extrusion molded plastics can be given many shapes. Due to the flexibility it offers, extrusion molded plastic can be used to produce various items. When looking to design a plastic extrusion, you can consider the following design tips.
4.    Plate with the shape of the part cut through the die with no transition guiding the material. This is a low cost design for low volume production.
5.    At the back of the die the edges and corners have radii to help the material transition into the die.
6.    The die aggressively channels the material evenly throughout the die. This design is most expensive and ideal for high volume jobs.

Consistent wall thickness is the most important aspect in the design of your part. It allows for an even flow of material through the die that produces more controlled parts with a lower tooling cost. It is advisable to avoid designing profiles with hollow sections as they add significantly to the cost of both the part and the tooling. While designing, it is always better to keep the thickness of the material uniform, avoid sharp internal corners and use open sections instead of closed ones. Advantages of plastic extrusion molding include low cost and the ability to produce intricate profiles.

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Plastic Machinery Manufacturing Industry in China's export situation analysis

China’s plastics machinery manufacturing industry 50 years from the 20th century produced the first product since, after almost half a century, especially the rapid development since the reform and opening up, and now have built a full range, the main technical and economic indices, or reached the international advanced level, supporting internationalized production gradually specialized, complete with large-scale industrial system, the product basically meet the domestic demand, rapid increase in export capacity. I. Current Situation of China plastic machinery manufacturing industry currently engaged in manufacturing plastics machinery and related enterprises, about 600 units, of which plastic molding equipment can provide about 250. China’s plastics machinery industry has a considerable scale, at present, China’s leading plastic machinery production capacity more than 10 million sets, which, out of more than 8,000 sets of equipment, 30,000 sets of injection molding machines, blow molding equipment, more than 3,000 sets of plastic machinery annual turnover of 8.0 billion ~ 10 billion yuan. Plastic products from the market analysis, combined with our existing plastic machinery production capacity into full play, from 2001 to 2010, China’s domestic market capacity of plastic machinery products the average annual growth of about 6%. 2000, 2005 were 80 billion yuan, 11 billion yuan, is expected to reach 14.5 billion by 2010. With the improvement in the quality of our products and variety increase, plastic machinery products in the domestic market share will increase as expected were 70%, 75% and 80%; plastic machinery products were 5.6 billion total industrial output value , 8.25 billion yuan and 11.6 billion yuan. With the increase of China’s exports in 2010, China’s industrial output value of plastic machinery products reached 140 billion yuan, 2.33 times in 2000, the annual average growth rate of about 9% in 2001 and 2005 annual growth rate of 10% 2006 to 2010 annual growth rate of 8%. Plastic machinery products from the quantitative analysis, 2000, 2005, were 5.5 million, 7.5 million units in 2010 to 10 million units, of which about 35% of the injection molding machine, extruder, 25%, about Blow Molding Machine 5%, 35% of other presses. Second, China’s exports of plastic machinery manufacturing industry of plastic equipment for general use in addition to meet the domestic demand, equipment exports also increased year by year. 3 years, China’s plastics machinery exports in the period of fastest growth in history. Long, exports have been about 50 million U.S. dollars in 1998, more than 100 million U.S. dollars in 2001 to 238 million U.S. dollars, up 31.09 percent over 2000. Experts believe that the future of China’s exports of plastic machinery injection molding machine will be based. From the quantitative analysis of the export is expected to share all kinds of aircraft were: 60.4% of injection molding machines, extruders 6.8%, 11.7% blow molding machine, the other presses 21.1%. From the amount of plastic machinery products export point of view, 74.1% of injection molding machines, extruders, 8.1%, blow molding machine, 8%, other plastic machinery products accounted for 9.8%. 3, plastic and rubber mold export Moreover, the rise of China Mould exports momentum. In 2002, China exported 19,500 tons mold, to 252 million U.S. dollars. Among them, the plastic or rubber mold to 467,800 units, about 172 million U.S. dollars, accounting for 68.3% of total exports of the mold. Major sources of exports of plastic molds to Guangdong, Zhejiang, Shanghai and Fujian Province, accounting for 57% of exports of the country mold, 13.9%, 11% and 5.2%. The main export markets are Hong Kong, China, Japan, China Taiwan Province, United States and Singapore, followed by Vietnam, Thailand, Malaysia, South Korea, India, Indonesia and Mexico. Although the origin of China’s plastic mold all over the country but mainly concentrated in the southeast coastal provinces and cities, especially in the Pearl River Delta and Yangtze River Delta area where the concentration. By provinces, the Guangdong Province and Zhejiang Province, the most developed. The two provinces produce plastic mold mold production accounts for about 2 / 3. , Dongguan, Shenzhen, Shunde, Guangdong Province, the most advanced plastic mold parts; and Ningbo, Taizhou, Zhejiang Province, is the most advanced producer. Plastic injection mold plastic mold of the key products, primarily serves the automotive, motorcycle and electrical industries.

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Plastics Directory: a Source for Captivating Products, or Technology for Making Such Products

With its malleability (plasticity) and ability to accept different colors, plastic is a material that can convert even day-to-day utility articles into decor items. And a plastics directory is your one-stop resource for all kinds of highly saleable products (or the technology and equipment needed to make them).

A quick look at some typical plastic products reveals the huge variety possible.

The Compact Disc (CD) in your computer or video player

The jerry can you use to store different kinds of liquids

The kitchen balance you use to measure out cooking ingredients

The plastic film that shows off your products as they are

The intriguing and fascinating range of toys that your children, or you, play with

The sturdy components made with engineering plastic

Replicas that can reproduce an uncanny look of the originals, such as ivory carvings and silk clothing (rayon)

A good plastics directory is your source for products to sell (or use). Or if you prefer to produce the products, the plastics directory’s sections on plastic machineries, equipment and materials could help you locate several suppliers of these, and get competitive bids.

Plastics Directory – A Niche Directory

The discussion in the previous section illustrates how niche directories are particularly valuable for a niche audience. Persons interested in plastics products would find a plastics directory the ideal resource to locate products, equipment and ever services (like consultancy services) they are looking for.

Very often, the directories accommodate only businesses located in specific countries. For example, a UK Plastics Directory might only list suppliers in the UK. This is a way to promote the businesses in one’s own country. In fact, such niche directories are sometimes produced by regional development agencies seeking to promote the development of specific industries in their regions.

Another way such niche directories provide value to their users is through specialized categories. Whereas a general business directory might have a single category like plastics, or a few categories like plastic machinery, plastic products and plastic materials, a niche directory could have more elaborate categorization.

For example, here is one classification system adopted by a plastics directory:

Plastic Films

Plastic Flow Control Equipment

Plastic Hardware

Plastic Injections Molding Tooling & Services

Plastic Materials

Plastic Packaging Machines, Equipment & Supplies

Plastic Products

Plastic Raw Materials & Supplies

Plastic Safety Equipment

Plastic Sheeting

Resins

(Source: http://www.plastics-malaysian.com/ )

It would be evident that with the above kind of categorization, specific users could organize their searching much more purposefully.

One way for the niche directories to add even more value is through how-to articles, market news and other resources of business interest. Such a plastics directory could be a complete resource for those interested in plastics.

Conclusion

A plastics directory is a good example of a niche directory. Such niche directories could provide much greater value to a niche audience than a general business directory. For example, more specialized and elaborate classification, tailored to the particular industry, would help readers to quickly locate the precise products or services they want. Supplemented with how-to articles, market development news, and such resources, these niche directories could add even more value.

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A Plastic Directory Can Play a Significant Role in Plastic Industry

A plastic directory is a business catalog of plastic manufacturers, plastic exporters, plastic suppliers, plastic products suppliers, manufacturers and exporters. Like other industry specific niche directory, the scope of a plastic directory definitely very tight to plastic industry. With specialized and elaborate classification, tailored to the plastic industry, a plastic directory can help its visitors to locate products or services easily and precisely.

Difference with business directory:

While a business directory add listing from more than one industry, as said above a plastic directory only add listing from plastic industry. A general business directory might have a single category like plastics, or a few categories like plastic machinery, plastic products and plastic materials. A plastic directory has specialized categories.

For example, here is one classification system adopted by a plastics directory:

Plastic Films
Plastic Flow Control Equipment
Plastic Hardware
Plastic Injections Molding Tooling & Services
Plastic Materials
Plastic Packaging Machines, Equipment & Supplies
Plastic Products
Plastic Raw Materials & Supplies
Plastic Safety Equipment
Plastic Sheeting
Resins

What features does a plastic directory offer?

Primary objective of a plastic directory add business from plastic industry via a detailed , organized and comprehensive category structure so that its visitors can locate the information precisely. A good plastic directory also offers
industry news and events
how to articles
market research information
market place
Advertisement service.
etc

What benefits does a business can get from a plastic directory?

A plastic directory can be a very effective marketing tool for its industry. As the users of the directory mainly of its industry, a business being listed in a plastic directory can reach to its potential customers. Traffic usually sends from such niche source are highly relevant traffic. The conversation rate of traffic from such source is much higher. Further trough its advertisement program, sponsored listing program a business can get more notice from the directory’s users.

If a plastic directory offers marketplace, a plastic business can also sell its product or service trough the market place.

More over the listing brings a directory link from a very quality source that search engines like. The link can help in search engine ranking which may result in more traffic.

Business from plastic industry should consider a plastic directory a very effective marketing tool as a part of its online marketing and promotion.

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Plastic Mold Basics

Plastic is one of the most used materials in the manufacturing of toys, tools, and other consumer goods. It’s very name, ‘Plastic’, from the Greek ‘plastos’ refers to ‘molded’. It is clear that the material plastic’s real value lies in the ways in which it is used and Plastic Mold. Plastic is extremely malleable, and allows or it to be pressed, extruded, cast, or molded into many different shapes and forms.

Plastics are used in a wide range of rapid prototype products, from every day office products such as pens, clips, and printers, to high-end uses such as TV’s, stadiums, and space shuttles. Before plastic’s wide adoption across many different industries, other materials such as wood, stone, glass, ceramic, and leather were the standard products used. Now, to find products made of leather and stone indicates a certain quality and ‘rareness’ because most of our ’stuff’ is plastic. Plastic has displaces all of these traditional materials and is now the dominant material in all of manufacturing.

The drawbacks to using plastic stem from its chemical makeup. The compounds comprising rapid prototype limit its ability to withstand heat and makes it vulnerable to hard impacts and weight. Plastics are limited in how dense and hard they can be made to be which causes many of these weaknesses. Additionally, plastics are not highly conductive of electricity, and so they are limited in use around electronic components. Additionally, the price of plastic molding and work limits its use as a building material (aside from PVC) in construction projects because it is still to expensive when compared to working with concrete and lumber.

Polyvinyl Choloride is an extremely useful plastic. Commonly referred to as PVC, it is used heavily in plumbing but also has many practical uses such as framing out large shapes and many other uses where tubing is involved. It other forms, PVC can be used in rain gear, packaging of food, shrink wrap, home siding, computer enclosures, and many other places in which most people don’t expect.

Plastic has truly revolutionized how the world operates. We now can have many tools and utensils because they can be developed and manufactured very cheaply with plastic. If plastic were not around, many of our standard household items would have to be made out of more expensive materials, thus limiting the ability for most people to obtain them. Plastic is cheap, extremely malleable, and very stable, and thus has many different uses which people all over the world have researched and continue to research to push the possibilities of plastic.

For research, data, and information on Plastic Mold visit Michael’s Plastic Mold Site.

There are a ton of links, resources, and data on plastic injection mold, machines, manufacturing, and more.