The injection moulding process is a widely used method for manufacturing high-quality plastic components with complex shapes and tight tolerances. It involves injecting molten plastic into a custom-designed mould, where it cools and solidifies into the desired shape.
Mold Design and Fabrication:
- CAD Design: A 3D model of the part is created using CAD software. The mold designers then create the negative (cavity) of the part, incorporating features like runners, gates, cooling channels, and ejection pins.
>DFM Optimization:
- Design for Manufacturing (DFM) principles help ensure the part is suitable for production with minimal waste and maximum efficiency.
>Mold Manufacturing:
- Molds are then fabricated using precision CNC machining for intricate details
Machine Setup & Material Preparation:
- Mold Mounting: The fabricated mold halves are securely mounted onto the clamping unit of the injection molding machine.
- Material Loading: Plastic pellets (e.g., Polypropylene (PP),
Polyethylene (PE), ) are loaded into the machine’s hopper. - Heating & Melting: The pellets are fed into a heated barrel where a reciprocating screw melts and homogenizes the plastic through friction and external heaters. The temperature is precisely controlled.
The Injection Moulding process:
- Clamping: The two halves of the mold are clamped tightly together under immense pressure to withstand the injection force.
- Injection: The molten plastic is injected under high pressure through a nozzle into the mold cavity.
- Dwelling (Holding Pressure): After the mold cavity is filled, a holding pressure is maintained to pack the plastic, compensate for shrinkage as it cools, and ensure the part fully conformsto the mold’s shape.
- Cooling: Water channels within the mold rapidly cool the plastic, causing it to solidify.
- Ejection: Ejector pins push the solidified part out of the mold cavity.
- Cycle Repetition: The mold then closes, and the process repeats for the next part.
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