There are many advantages to choosing China plastic injection molding. These advantages include price, quality, transportation, and delivery. So if you are looking for a plastic injection molding company, then I suggest you read this article carefully. This article will allow you to understand how to choose injection molding.
Injection molding is a making method of plastic products, It is the preferred production method for most mass produced plastic products, due to its high output rate and consistency of quality. Its program is the molten plastic by pressure injection into plastic products mold, cooling and solidifying molding to get all kinds of plastic parts.
There are special mechanical injection molding machines for injection molding. At present, the most commonly used plastics are PC, polyethylene(PE), polypropylene(PP), ABS, Nylon, polystyrene, etc. Almost every plastic part around you was manufactured using injection molding: from automotive to electronic appliances, and to your mobile phone and computer.
Plastic injection molding is employed for a wide range of aesthetic and functional purposes in many industries and applications, such as Medical Devices, Appliances, Electronics, Consumer goods, Agricultural, and Automotive.
These products include but are not limited to:
● Automotive parts – dashboards, bumpers, grilles, light shell, lenses, handles
● Electronic components – electrical connectors, enclosures, protective connection
● Medical devices – syringes, valves, dishes. Pipette, Forehead Thermometer shell.
● Consumer goods – mobile phone cases, keyboard, food box, water cup. computer
● Furniture parts – seat cushions, chairs, seat covers.
● Home Appliance - wash machine, TV, air conditioner, air cleaner,
● And more.....
1) Overmolding
It is a type of injection molding. Overmolding is a two-step process where a second injection is molded over top of the first injection. It is helpful in industries where they need to manufacture multip material in whole plastic parts. Usually, You’ll often find this on parts to improve grip by adding elastomer to the handle.
2) Insert Molding
Insert molding is a process that begins with one or more inserted components placed into the mold before resin enters. The material is then injected and flows around the insert(typically is metal magnet brass ceramic or other hard product), to form the final part. In our life, screwdrivers are our most insert molding product in common.
3) Gas Assist Injection Molding
Gas assist molding is used specifically to mold parts with very thick sections. Plastic forming process where a plastic melt is injected into a mold and where also gas is injected for pushing the melt towards the mold's internal walls where the melt is solidified.
During the molding process, the gas is introduced inside the part geometry. The gas displaces a portion of the molten plastic inside thick geometry and then performs the packing forcing the polymer to melt against the external walls to create a hollow channel through the thick region and a packed-out appearance.
4) In-mold Decoration or In-mold labeling
In mold decoration(IMD) or In Mold Labeling (IML) is an injection molding process whereby the decoration of the plastic part, using a label, is produced during the plastic injection process.
Simply put, a preprinted label is inserted via automation into the cavity of an injection mold and plastic is injected over the label. This produces a labeling plastic part in which the label is permanently fused to the part itself.
5) High Temperature Injection Molding
High temperature molding is an injection molding with materials such as PEEK PFA PEI PPS PPO PPSU PAI LCP PES PAS etc. It is unique to the current injection molding is the temperature higher than the regular molding, to 400℃ than the current about 200℃.
Through the high temperature melt, and the high temperature of the rotating and reciprocating screw, pass by the injection chamber, reached the cavities, after a slightly longer seconds cooling system formation products completed.
6) Thin Wall Injection Molding
Thin wall parts have a wall thickness of less than 1mm. Thin wall molding is a specialized form of conventional injection molding that focuses on mass production of plastic products that are thin and light, without structural compromise, in order to achieve material cost savings and shorter cycle times.
Faster cycle times improve productivity and lead to lower costs per product. In order to produce thin wall products, high speed injection machines high quality molds are high level processing technology is all indispensable.
4. How to Customize Injection Molding
Although on the face of it, the injection molding process may seem simple, there are many critical points that need to be tightly controlled to ensure the overall quality of the plastic components produced.
In order to keep this as basic and simple as possible, we broke down the plastic injection molding process into 5 parts:
1) Selection the Right Raw Material
How to choose a material for your parts, The material should be identified based on how the final product will be used and where to used it. The material could be rigid or flexible, strong or brittle depending on its use. Material’s relevant properties might include mechanical, physical, chemical resistance, heat, electrical, flammability, or UV resistance. Usually, consider as following:
Here is some resins variety in common
1) PP(Polypropylene) – it is an elastic, tough, and fatigue-resistant semi-crystalline thermoplastic. It is used in packaging materials, automotive parts, and household and office items. Despite its semi-crystalline nature, it has low melt viscosity, hence it can easily flow out of the injection chamber which makes molding easier.
2) ABS(Acrylonitrile-Butadiene-Styrene) – It is a great choice for a vast majority of parts. It’s reasonably priced, strong, relatively tough, has a decent appearance and is forgiving even if you don’t follow all the standard design rules for plastic parts. The famous toy Lego Bricks are made from this material.
3) PS(Polystyrene) – A hard thermoplastic that is a cheap and transparent material. The clear degree looks nice but very crispy.
4) Polyethylene – has several types which are differentiated based on their densities; these are low-density polyethylene (LDPE), medium density polyethylene (MDPE), and high-density polyethylene (HDPE), and ultra-high molecular weight polyethylene (UHMWPE). Polyethylene is also a thermoplastic. They are lightweight, have good chemical resistance, and are impermeable to liquids and gases. Polyethylene with higher densities has higher tensile and flexural strength and toughness, but has poorer elongation and exhibit brittleness in low temperatures. They are used in a wide range of applications which include packaging materials, medical devices, rigid containers, and bulletproof vests.
5) PC(Polycarbonate) – A high-performance plastic material, with high impact strength stability and optical properties, alongside some good electrical properties. but price higher than ABS. One better choice for clear products.
6) Nylon – Available in a range of types(PA6, PA66.PA6+GLASS FIBER, PA66+GLASS FIBER). Typically, nylons have good temperature and chemical resistance and can absorb moisture.A very strong material that flows well, especially for thin parts. Can be susceptible to shrink and warp, particularly glass fiber-filled nylon.
7) PMMA(Acrylic) – It has called plexiglass. The best choice option for transparent plastic products although they can be brittle.
8) POM – It is an engineering thermoplastic used in precision parts requiring high stiffness, low friction, and excellent dimensional stability.
2) Engineering Product Design
Designing plastic parts is a complex task involving many factors that address application requirements. Adhering to some basic rules of injection molding product design will result in a part that, in addition to being easier to manufacture and assemble, will typically be much stronger in service.
Part design is going to be absolutely critical when it comes to manufacturing an injection molded part. You have to ensure the part is designed with the injection molding process in mind. According to the customer's inquiry, we design the parts, but we have to follow some basic design principles.
Some Critical Product Design Elements Include:
1) A Uniform Wall Thickness
Uniform Wall thickness is very important, Non-uniform wall sections can cause warp sink marks and dimensional control problems defects. It is best practice to maintain a uniform thickness throughout an injection molding part.
When this can’t be achieved, there should be a gradual transition between the thick and thin sections by blending or chamfering. It is also best practice to gate into the thicker section and then flow into the thinner section. Overly thick areas should be avoided, as they can lead to sinking marks.
We recommend walls to be no less than 40 to 60 percent of adjacent wall thickness and all should fit within recommended thickness ranges for the selected resin.
The chart below shows recommended wall thicknesses for common injection molding resins:
2) Rib
A rib is used to add strength and support to features like bosses and walls. To prevent shrinking, rib thickness should be 50-75% of the wall thickness to minimize the sink caused by the thick section where the rib and wall meet.
3) Undercut
A portion of the part geometry would prevent the part from being ejected from a straight-pull mold without a portion of the mold passing through (and destroying) the part. Mold designers must consider how to solve the problem and won’t affect the part strip.
4) Snap Fits
Snap fits are often used to hold plastic parts together because they are quicker and lower cost to implement than screws.
Snaps inherently require an overhanging feature which is often undercut, however, to keep costs low it is often possible to create snaps in line with the draw using the parting line
and shut-off.
There are many ways to create a snap-fit. The snap design will depend on a number of variables specific to your project including space available:
● Material choice
● Snap force
● Retention force
● Opening requirement
5) Sink Mark
When the hot melt flows into the injection mold, the thick sections don’t cool as fast as the rest of the part because the thicker material becomes insulated by the outside surface of faster cooling plastic. As the inner core cools, it shrinks at a different rate than the already cooled outer skin.
This difference in cooling rates causes the thick section to draw inward and create a sink mark on the outside surface of the part, or worse, completely warp the part.
In addition to being unattractive, the mark also represents added stress that is built into the part. Other less conspicuous areas where sink occurs include ribs, bosses and corners. These are often overlooked because neither the feature nor the part itself is too thick
6) Corner Radius
The closer to a 90-degree angle, the harder it is to inject molten plastic into the corner of your parts. Consider the proper radius to optimize material flow and part integrity. adding smooth transitions between features. All inside and outside corners should have fillets to avoid stress in the molding parts.
7) Material selection
Defining the material selection at the design stage is critically important to ensure performance characteristics can be met since each material has a different shrink, wall thickness require, and physical performance a material change can cause parts to underperform or fall out of tolerance.
3) Mold Design
Mold design also must follow some basic design principles. Some of critical elements include:
1) Shrinkage
Shrink tolerance depends mainly on part design and resin choice. It is generally between 0.4 - 2% and must be taken into account by the mold designer. The exact amount of shrinkage depends on several factors, including material, process conditions, and gate location.
2) Draft Angle
One aspect of mold design that cannot be overlooked is the easy removal of the final product from the mold, with no damage to the surface of the part.
The draft angle depends on several factors, including design of the part, material, depth of the mold cavity, surface finish, texture, and amount of shrinkage. Generally, the deeper the cavity, the more draft is required. 1 to 2 degrees draft works well in most scenarios.
3) Gate
This is one of the most important factors to consider during the Filling Stage of the injection process. a gate is an opening in the injection molding mold that allows the resin to enter and fill the cavities. Injection gates vary in size and shape depending on the part design(like shape wall thickness ribs surface roughness)and resin material.
Designers must take into account a number of factors to determine gate types and locations to achieve optimum flow, fill pressure, cooling time, and dimensions/tolerance. It is important to locate gates where they won’t impact part performance or appearance (flow marks, shrinkage, warping). Below are our common types of injection molding gates.
● Edge gate
● Tunnel gate
● Direct/sprue gate
● Pin gate
● Cashew gate
● Fan gate
4) Gate Location
To avoid issues arising from your gate location, here is a few experiences on proper gate location:
● Place gates at the heaviest or thickest cross section to increase material feeding and minimize voids and sink.
● Minimize obstructions in the flow path by placing gates away from cores and pins.
● Be sure that stress from the gate is in an area that will not affect part function or aesthetics.
● For a high shrink grade material, the part may shrink near the gate causing "gate pucker" if there is high molding in stress at the gate.
● Be sure to allow for easy manual or automatic degating.
● The gate should minimize flow path length to avoid cosmetic flow marks.
● In some cases, it may be necessary to add a second gate to properly fill the parts.
● If filling problems occur with thinly walled parts, add flow channels or make wall thickness adjustments to correct the flow.
5) Side Actions
Injection molding side actions are inserts (sometimes referred to as “features”) added to the mold in order to create undercut geometry. Undercut features are perpendicular to the main parting line and cannot be produced with a straight-pull mold, or in other words, by pulling apart the two halves of the mold and ejecting the part.
When side actions are added to the mold, they allow material to flow around them to form the undercut feature. The side actions must then be removed manually or automatically to allow part ejection.
Common types of side action:
● Slide - Slides create and release external undercut features by collapsing into place via a cam as the tool closes. It then pulls away as the tool opens.
● Lifter - Lifters can also be used to create undercuts. A lifter moves with the ejector pins but at an angle, so as the pins push the part off, the lifter moves outwards and away from the feature. This can be quite cost effective as it is a relatively simple and automatic process.
There are however some constraints on geometry to allow for the moving tool parts.
● Unscrewing action - An unscrewing action is an automated motor or manual hand screwing that creates screw or threaded features. These actions prevent damage to the threads with careful unwinding between cycles.
● Collapsible Core - they are mechanisms that release a circular undercut feature in a method similar to a lifter. These allow the actions to collapse inward, providing clearance for part ejection.
6) Molding/Runner System
Molding systems can be cold runner molds or hot runner molds. A cost/benefit analysis is the best way to determine which system to use given the specifics of a project.
Cold runner molds - generally easier to produce and maintain, lower mold cost, but more material waste.
The cold runner system is the channel that guides the melted plastic into the cavity of the mold. It controls the flow and pressure with which the liquid plastic is injected into the cavity and it is removed after ejection. The runner system usually consists of 3 main sections:
● The sprue is the main channel through which all the melted plastic initially flows as it enters the mold.
● The runner spreads the melted plastic along the face where the two halves of the mold meet and connects the spur to the gates. There may be one or more runners, guiding the material towards one or multiple parts. The runner system is cut off from the part after ejection. This is the only material waste in injection molding, about 25% of which can be recycled and reused.
● The gate is the entry point of the material into the cavity of the mold. Its geometry and location are important, as it determines the flow of the plastic.
Hot runner molds - less material waste, control exact, high efficiency, but higher mold cost.
7) Cooling System
Proper placement of cooling channels in mold walls to circulate water are also essential for cooling to create a final product with homogeneous physical properties, resulting in repeatable product dimensions. Uneven cooling may result in defects called “hot spots” - areas of weakness that affect repeatability.
The cooling system design needs the following remarks.
● Need to make cooling channel near the biggest thickness of products
● The diameter of the cooling channel usually is bigger than 8 mm
● Increase the number of the cooling channel rather than enlarge the diameter and length of one cooling channel
● Make sure core insert, slide core,… can be cooling. If not cold must change the mold design
9) Ejector System
Common ejector options include pins, blades, sleeves, bars, stripper plates, bump offs and lifters. Each option brings tradeoffs. Different ejection options will leave different sizes and shapes of marks on the part and require different levels of maintenance.
● Ejector Pin
Simplest and most economical method. Ejector pins are located on the B-side half of a mold, from which they push the formed part out of the mold. The pin mark of an ejector mold is commonly imprinted on finished products as a dent.
● Blade ejector
When ejector pins can't fit within the allowable ejection area, blade ejectors offer a good alternative. These flat, rectangular pins can eject on thin part regions. Plastics engineers use blades to eject on ribs because of the narrow but deep ejection requirements
● Ejector Sleeve
Ejection sleeves distribute force evenly across small, circular features. Two components make ejection sleeves: a hollow sleeve and a smaller solid core pin that fits inside. The pin typically forms a part feature and extends past the sleeve in the mold’s unactuated state. The part forms onto the pin, and the sleeve moves when the ejection system actuates, pushing the part out of the mold.
● Stripper Plate Ejector
Also called plate ejection system, this is an election mechanism that works by pushing and pulling them off the mold crate once the cooling process is done. This is done through peripheral contact that’s applied around the component base.
The stripping action provides the molding manufacturers with benefits like a clean ejection that ensures the final product doesn’t sustain any damage or distortion along the way.
● Lifter
Used primarily to form undercuts, Unlike vertical ejection systems, lifters angle in the core plate. This allows the lifter to clear the undercut for ejection to take place.
● Bump Offs
Small undercuts can be designed to be safely ejected from a straight pull mold without the need for side action. This gives obvious cost savings.
The basic principle is to allow the plastic to deform as it is ejected. Plastic choice is important. such as polyethylene is flexible, but glass filled nylon would be too stiff. The feature needs freedom to deform – once the cavity has moved away. The geometry should be designed to allow movement and flex.
In the example after the cavity is moved away the part is free to easily stretch “bumping over” the undercut feature. Bottlecap threads and small snap features are often created using this approach.
10) Texture
Texturing is an integral piece of overall product development and should be considered during the design process to achieve the desired results. Texture can be a functional component of design (for example, to improve grip), as well as a strategy for camouflaging imperfect or frequently handled parts. Texture can also be used to reduce part wear from friction.
A wide variety of textures are available for injection molded parts such as:
● Matte Finish
● Multi-Gloss Patterns
● Graphics
● Leather Grains
● Woodgrain
● Layered Textures
● Images
● Logos Incorporated into the Pattern
● VDI standard surface texture
● MT standard surface texture
If the texture is on a parallel surface with the mold opening, however, the increased draft is necessary to prevent scraping and drag marks that could occur during part ejection.
11) Venting System
In a mold, a shallow channel or minute hole is cut in the cavity to allow air to escape as the material enters. Regular venting way，
A) Parting line or parting line groove (advantage: simple, low cost)
It can be placed anywhere along the parting line in particular they should be located in areas that are the last to fill in a particular section of the injection mold
B) Ejector pin or Pin or insert (advantage: simple, low cost)
If the air is trapped with no way out to the injection mold parting line, it is advisable to place a venting pin/ejector pin to permit the air to escape through the clearance between pin and hole.
C) Sintered metal insert Vents (disadvantage: simple, low cost)
They are unique venting plugs composed of a large number of straight, parallel and uniform pores made through a powdered metallurgical process. The pores allow trapped air or gas to escape from the mold cavity during the injection molding process, thereby reducing the occurrence of short shots and burned parts
D) Especial equipment, such DME vacuumjet+ (disadvantage: cost high)
12) Text
In our mold making process, the text is final operating except for some special. like cavities number, logo. Usually, we use laser engraving to create these texts.
4) Mold Making
Building the mold the right way and with a trusted partner reduces costs in project delays or product defects. The mold may be the largest investment in the project. That means it’s even more important to get it right the first time.
1) Selection of the Right Steel
The proper grade of steel must be selected so components that run together do not wear out prematurely. Steel hardness must also be determined to maintain the proper balance between wear and toughness. Most molds are made from hardened or pre-hardened steel. Hardened steel (heat-treated after machining) has superior wear resistance compared to pre-hardened steel and lasts longer. Typical hardness ranges between 50 and 60 Rockwell-C (HRC).
2) Standard/CNC Milling
In its conventional form, standard machining requires the manual use of lathes, milling machines and drill presses. With advanced technology, CNC machining has become the predominant means of creating more complex and accurate molds, while still using standard machining methods.
In modern CNC systems, the mold design and manufacturing processes are both highly automated. The mold’s mechanical dimensions are defined using computer-aided design (CAD) software and then translated into manufacturing instructions by computer-aided manufacturing (CAM) software. “Postprocessor” software then transforms these instructions into the specific commands necessary for each machine used in creating the mold. The resulting commands are then loaded into the CNC machine.
3) Die sinking Electrical Discharge Machining/Ram EDM./Sinker EDM.
Electrical discharge machining(EDM) has become widely used in mold making. EDM is a process in which the desired shape is obtained through the use of an electrode, which is fabricated out of graphite or copper.
using a controlled electrical source, the electrode is used to destroy and disperse the metal in the area opposite the electrode. The electrode never contacts the workpiece. A spark gap of a few thousandths of an inch is always maintained between the electrode and workpiece.
EDM advantages
● It can produce shapes that are not possible with conventional CNC machining. Like very sharp corner,thin ribs(such 1-2mm rib), very deep shape.
● It can process pre-hardened molds to be shaped and eliminates the need for additional heat-treating
● High flatness or high quality curved surface use mirror spark erosion. The surface of EDM. erosion surface is the final part finish without any polishing.
4) Wire Electrical Discharge Machining(WEDM)
Wire EDM, otherwise known as wire erosion. Like the sinker EDM, the wire EDM uses an electrical current to remove material. The difference is that instead of using a machined electrode, a wire is used to cut a narrow channel through material. The wire is continuously moving so that it does not wear and break due to the corrosive nature of the EDM process.
The wire EDM is extremely accurate and used for making mold inserts, mold core, mold cavities, slide, ejector pin holes. Like the sinker EDM, the wire can cut hardened material with ease. it is very well-suited for producing small parts because of its high levels of precision.
The wire is usually very thin, with a diameter of around 0.05mm to 0.35mm. A fresh wire is automatically spooled throughout the machining process to avoid using burnt wire and to ensure precise cutting.
5) Surface Polish and Texture
The most common way to specify injection molding surfaces is by using SPI(the society of industry), VDI and Mold-tech standards. Injection mold toolmakers, manufacturers and design engineers worldwide recognize these three standards and SPI standards are marginally more common and widely known as SPI grades.
A) SPI Injection Moulding Surface Finish
The Society of Plastics Industry Association (SPI) is an independent US trade organization. These standards in the US plastics industry identify the cosmetic quality of plastics. Their surface finish standard for injection molding tools is accepted across the industry. The SPI standards specify 12 grades of mold finish in four different categories that range from mirror-perfect to dull.
● Gloss finish – Grade A ( Diamond finish )
Grade A finishes are considered the highest standard. It is specified high gloss finished on hardened steel molds buffed to a mirror luster with fine diamond powder suspended in oil. also called “Diamond finish”. These finishes are super smooth, shiny, and expensive to make plastic optical parts, like automotive lenses, light and other optical goods.
● Semi-gloss finish – Grade B
Grade B specifies semi-gloss finishes with some sheen on hardened tool steel molds polished with ultra-fine grit sandpaper or emery cloth. These plastic parts can’t show mold, tool, or machining marks.
● Matte finish – Grade C
polished using fine stone powder. Sometimes called stone finish, it provides good release and helps hide machining marks. Grade C is also the first step of grades A and B surface finishes.
● Bead blast – Grade D
typically sand or glass beads, will result in non-directional patterns and dull or flat finishes.
B) VDI Surface Finish
VDI 3400 surface finish (commonly known as VDI surface finish) refers to the Society of German Engineer mold texture standard and is widely used by mold manufacturers worldwide, including in North America, Europe, and Asia. The VDI 3400 surface finish is mainly treated using Electrical Discharge Machining (EDM) when mold machining. However, it could also be done by using classic texturing techniques such as laser etching or Sandblasting.
C) Mold-Tech surface texture
These under the Mold-Tech standards, they are made through chemical etching or laser etching modification of the mold cavity. Each is represented by an MT- followed by a five-digit code. For example, MT-11010 presents a sand-like appearance, MT-11120 resembles smooth concrete, while MT-11555 has a wood panel look, and so on.
5) Production Process
To keep the manufacturing process as simple as possible, we broke it down into 4 stages. the 4 Stages of the Plastic Injection Molding Manufacturing Process includes:
A) Feeding and melting the raw material stage
Injection molding machines can be powered by either hydraulics or electricity. All-electric injection molding machine is the trend of the industry, it can provide lower cost, higher accuracy.
raw pellets of material are fed into the hopper at the top of the machine. As the screw turns, these pellets are fed gradually into the barrel of the machine. The turning of the screw and the heat from the barrel gradually warm and melt the thermoplastic until it is molten.
Maintaining the right temperatures within this part of the process is critical to ensuring the plastic can be injected efficiently and the final part formed successfully.
B) Injecting the plastic into the mold stage
The screw pushes the molten plastic into the mold cavity where it takes form and begins the cooling stage. This phase is important because if not enough pressure is used, the cavity will not be packed completely, resulting in quality issues. Part size shape and wall thickness will determine the injection molding pressure and time that is required.
C) Holding and cooling time stage
Once most of the plastic is injected into the mold, it is held under pressure for a set period. This is known as holding time and can range from milliseconds to minutes depending on the type of plastic and complexity of the part. This holding time is key to ensuring that the plastic packs out the tool and is formed correctly.
After the holding phase, the screw draws back, releasing pressure and allowing the part to cool in the mold. This is known as cooling time, it can also range from a few seconds to some minutes and ensures that the component keep correctly shape before being ejected.
D) Enjection and secondary operation processes stage
After the holding and cooling times have passed, ejector pins or plates eject the parts from the mold. Parts drop into a container at the bottom of the machine or picked up by the automatic robotic arm. In some cases, such as trim flash have to been done, which can be completed by other machinery or operators.
Usually, with flash parts is a uncooperative product. Must adjust mold until approved. Once these processes are complete, the components will be ready to be packed up and ship to customers. Certainly, some secondary operation maybe is necessary for some consumer goods or surface request products. like plating, pad printing, screen printing, paint, ultrasonic welding and assembly and so so.
Injection molding is a complex process and the company you choose should have plenty of resources to help you create the best plastic part possible. it is important to consider some crucial factors while choosing a plastic injection molding company. Your ideal partner during the process should be able to suit your industry, your products, and product requirements.
1) Production Capabilities
It is important to verify before starting any project that your supplier has the capabilities you need. When you work with a molder that offers multiple presses in various sizes, they have the ability to undertake the entire project while using like materials and colors.
It’s also important to understand any capacity constraints your supplier may have in relation to project timing. A partner who has the necessary machinery and utilizes the latest technology will be able to help you quickly scale production up or down to meet market demand without having to search out and qualify a new contract manufacturer. This type of versatility can save time and money.
Automation has a profound impact on the efficiency of injection molding. Those that incorporate the latest design and production capabilities will provide competitive prices in comparison to other alternatives. Over the years, the advancements in automation manufacturing processes have impacted the plastics industry at a high level. Not only has it allowed businesses to improve in the areas of cost and turn-around time, it has also allowed plastic part producers to lower the likelihood of defects and increase the overall quality of products created.
2) Experience and Expertise
Look for an experienced your industry products manufacturer that already has the equipment, facilities, personnel, vendor relationships, design knowledge, and other specialized skills is necessary. An experienced manufacturer can help you anticipate problems and offer solutions in advance. Not only will this experience bring expertise to your project, but it also ensures that the manufacturer you choose has the equipment and infrastructure necessary to do the kind of work you’re planning.
Personal experience is important as well, so look for a company with experienced professionals at all levels to make sure that you have access to the quality of work that you need.
3) Quality Assurance
The quality of your product is of the utmost importance, so must select an injection molding company with a solid track record and a clear commitment to quality assurance, high standards, and customer satisfaction. Ensure that the plastics manufacturer you choose is respected and meets your quality standards and those in the industry. Consider companies who communicate with you clearly and honestly, and welcome those who welcome you with offers to visit the facility.
4) Lead time consideration
Making a mold for a plastic injection molding part can range from 4-12 weeks. All representatives involved in the process should factor design revisions, part complexity, communication between designers, engineers and other individuals involved in the process, as well as account for unexpected events like shipping delays, etc.
It’s always best to communicate your time constraints with an injection molder partner as early as possible to gauge their capacity and ensure you get the final production parts in hand on time. plastic parts which have specific design needs need to be carefully discussed with the injection molder. It is important to communicate your expectations and challenges to your chosen plastic injection molding company
5) Value
Price is always a top factor for a manufacturer when determining the best injection-molding partner. Budgets and ROI calculations are a part of doing business.
Sometimes a bargaining deal may result in costly repairs a few months later. Many elements come into play when considering the overall price for part production and more goes into a long-term relationship than just choosing the lowest quote. While the lowest priced option may seem like the best solution, it could cost you more money in the long run.
Consequences from poor design and material selection, issues that arise during production and ultimately missing a product launch can quickly add additional costs. Consider the overall value of the service that is being provided, the quality of work and your partner’s ability to be a vital resource to you and your team.
6. Company and Product Advantages
Amazing Plastics is a specialized custom manufacturer in manufacturing injection mold and plastic parts including automotive parts, medical parts, industrial parts, optical components, electronic and electrical components, etc. we have a professional team with rich experience to build high-quality molds and products for our customers. And we have the strength of short lead time, high quality and trustworthy after-sale services.
We have several advantages over plastic products and production:
1) Quality Assurance
● First Article Inspection (FAI)
● Statistical Process Control (SPC)
● CMM Control
● Visual Check
2) Excellent Mold making capabilities
● Experienced mold designer
● Each insert inspection including tolerance, surface finish. Ensure high precision mold accessories
● Advanced mold processing equipment, Sodick Surface Erosion EDM, Mitsubishi Wire Cut EDM, 5-axis precision CNC milling
● Lifetime Free Warranty on Mold
3) Production Capabilities
● Expertise with a Range of Materials
● Advanced injection machine(25 sets all-electric Haitian injection molding machine)
● Experienced injection engineer provide technology support
● Advanced Automatic Servo Robotics & Vision System
4) Competitiveness Price
● Automatic reduce cost
● All-electric injection machine save cost
● Production process control to reduce the defect rate
5) Kitting service
● Ultrasonic welding
● Pad printing
● Sink screen printing
● Laser engraving
● Plating
● Painting
7. Chinese VS Foreign injection molding
If you require plastic injection molding services to create a plastic part, one of the first—and most critical—decisions to make is whether you’re going to go with a plastic injection mold service in-house or one based overseas. While many countries offer mold-making services, China is the primary player in this market.
You might be leaning toward China because their plastic injection molding services are generally low-cost — you’ll likely save between 20-60% with an injection molding made in China. You may also achieve faster results.
It boils down to the fact that Chinese plastic product manufacturers have a comparative advantage and offer products with extremely high cost performance.
1) Superb engineering support
Experienced tooling and products expertise. without it, you could end up with a mold that has to be thrown away or completely retooled.
2) Experienced designer
Plastic injection molding creates complex parts with absolute uniformity and coherence. Millions of virtually similar parts are made from this technique. The manufacturers in China take into account the key elements to maximize the impact of plastic injection molding. Due to optimized plastic injection molding, it is possible to create high-quality precision parts.
Since the molds are subject to extreme pressure themselves, the plastic within them presses harder. It is very easy to make complex parts with consistency and quality with the right designs.
3) Competitive price
Based on design analysis and functionality assessment, injection molding in China use mold flow simulations to determine the factors that can reduce a significant level of costs. A molder will opt to conduct a design study for manufacturability to identify if there are modifications that should take place in the tooling and production phases.
This is also the stage wherein the manufacturability study can generate a profit because there will be significant time savings for precautionary measures and the prevention of mold defects. Plastic injection molding can give many industries a competitive advantage since it will explore many potentials when it comes to production.
4) High quality products and service
As a powerhouse in the world of plastic, Chinese mold and plastics products manufacturers can provide your company with extensive knowledge and expertise when it comes to plastic injection molding. This factor should result in having better quality molds which will eventually be evident in your plastic products. The overall efficiency of the manufacturing process will not only impact your production but your entire business operation.
8. 5 Essentials for Best Quote
Here are the five essential items that the plastic injection mold shop will need from you so they can give you an accurate quote:
1) What types of resins or polymers are needed for the part?
Do some research. By knowing the type of plastic material that will be best for your project, you’ll be giving the molder a reference point. A skilled molder will suggest the additives and/or resin they feel will offer the best outcome.
2) What is the complexity and size of the part?
Although injection molding is used to make many plastic parts, other molding processes may also be used. Generally, the injection molding process is ideal for making small, more complex parts. Using compression or injection molding, larger parts can be manufactured. Whole hollow objects such as bottles are manufactured with blow molding, extremely large parts are made with rotational molding.
3) What quantities are required?
Every injection mold is made differently. If you’re interested in a shorter production run or smaller quantities, using an aluminum mold will be your best bet. However, if your project requires huge quantities over an extended period of time, you should go for hardened steel mold. While the upfront cost of the latter is greater, it pays for itself down the line. Precision, large-volume molders like Amazing Plastics is expert in creating tools with hardened steel.
4) What is the part supposed to do?
Will the part be exposed to any environmental or chemical issues? The injection molder you’re working with must understand the part’s application. This would let the manufacturer know how sturdy should the part be and what the wear and tear will be over time. The information you offer will help your molder suggest the additives and/or resins needed for your project.
5) Are there samples or CAD drawings of the part to be quoted?
The molder should understand what you’re asking them to make. Otherwise, they’ll not be able to give you an accurate quote. By providing comprehensive dimensional drawings of the part, you can help them understand the complexity and size of the part. A prototype or sample can help the molder determine how to maximize the design for manufacturability.
9. Conclusion
From the above contents, we can know how to select injection molding from different aspects: The basic knowledge will help to understand what is injection molding, what types of injection molding, and what applications of injection molding can be used. The information on injection molding production and injection molding manufacturers provides the ways and options that you can choose reliable injection molding suppliers. Chinese injection molding has several advantages compared to foreign, especially the high performance price rate is invincible, that’s the reason why more and more importers and distributors are custom plastic parts from China.
Here at Amazing Plastics, we specialize in in-house mold making services as well as plastic injection molding services for small- to mid-size companies. We know you’re making some critical decisions right now that’ll affect the quality and efficiency of your future plastic parts, so if you have any questions at all about Amazing Plastics’s process for mold-making or injection molding, we’d be happy to help answer them, welcome to contact us!
