Tag: plastic

Typical Plastic Injection Molded Parts

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Typical Plastic Injection Molded Parts

Plastic injection molding technology consists of feeding plastic material into a heated barrel. The material is mixed and then led into a mold cavity, where it takes shape and hardens into the final product.

What you might not know is that plastic injection molding has a bevy of advantages and benefits over comparative plastic processing and manufacturing methods. Plastic injection molding is such a precise method that it can fabricate nearly any type of plastic part. There are certain design restrictions, but the molds that are made allow the finished product to be very precise. This makes it a very widely used production method. With such accuracy and precision, plastic injection molding is used in almost everything you touch in some form or another.

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The History of Plastic Injection Molding

When you really stop to think about it, it’s hard to imagine a world without plastic. Plastic is used in such a wide variety of products. Its versatility makes it perfect for anything from simple lunch boxes to more complex things.

But before plastic and injection molding were discovered, mankind had to make do with more natural materials, like wood ivory and metal.

The rise of plastic injection molding started with Charles Goodyear’s discovery of vulcanization. After this, various contributions to the development of plastic were made by scientists and inventors through the 19th century, making plastic a common material used to mass produce household items by the mid 20th century.

Plastic Injection Molded Parts in Different Industries

It’s easy to think of things like containers, bottles and other common plastic goods. But plastic injection molded parts are required for most industries nowadays. Examples of industries that need plastic injection molded parts include:

Technology

While things like cellphones, computers, televisions and even USB memory sticks need a lot of parts made with metals, these items always feature some plastic molded parts too. Phone and computer covers, or often times even screens, are made from injection molded plastic.

Medicine

Medicine is a lot like another branch of technology, and so many things doctors use on a daily basis (even in surgical theaters) are made of plastic.

Automotive industry

While the engine, doors and wheels of a car aren’t made of plastic, the interior of most vehicles are filled with plastic molded parts.

Construction

Once again, barely anyone thinks about plastic molded parts used to build, but plastic is used to make things like plumbing pipes and electrical switches, for instance.

Fashion

In the fashion industry, injection molded plastic parts are often used for items such as buttons and buckles. And while polyester material isn’t injection molded, it’s worth mentioning that even a lot of materials used to make garments are made from plastic.

In reality, it’s hard to think of an industry that doesn’t use plastic molded items for some purpose. Even CD’s and DVD’s are made from injection molded plastic. And before CD’s and DVD’s cassettes were made from plastic too!

Benefits of Plastic Injection Molding Parts

When you stop to take a look at the plastic injection molding process, it’s no wonder plastic is such a commonly used material in the 21st century. There are multiple benefits to plastic and the injection molding process that aren’t possible when using a different process or material:

  • Flexibility: Because there’s such a wide variety of different plastics available, injection molding is a good process to produce products with different qualities regarding durability, resistance to temperatures and hardness.
  • Production speed: Plastic injection mold cycle times make it easy to mass produce products and create hundreds of plastic injection molded parts every day.
  • Precision: With a good mold, every plastic injection molded part will be an exact duplicate of the previous. Molds can also be designed to create highly detailed parts that can be easily mass produced.
  • Cost effectiveness: Compared to other production processes, plastic injection molding is by far the most cost effective for mass producing parts.

Although other materials and production processes will never become redundant, it’s clear to see why plastic has become one of the most commonly used materials in the 21st century.

Producing Quality Injection Molded Parts

Plastic injection molding by far outperforms a process like 3D printing for mass producing parts. But even though plastic injection molding may seem easy, it’s not. Producing plastic molded parts requires knowledge about different plastics, their melting points and how the injection molding process works.

A high quality plastic injection mold is also an essential part of molding parts that are free of defects, such as flow lines or surface delamination. Because of this, it’s worth investing in a high quality plastic injection mold.

Too many plastic injection molders try to save on a mold by importing from abroad, but this is rarely worthwhile. When you buy from an American injection mold manufacturer, you can usually count on better quality and mold design. Because your injection mold manufacturer is closer, it’s also easier to arrange for molds to be regularly maintained, so ensuring you get the most out of every mold!

Tips for Designing Plastic Injection Molded Parts

Injection molded plastic parts have some magnificent advantages including versatility, the capacity to make simple to super complex parts, and consistency, the capacity to make hundreds of thousands of parts. Be that as it may, the building and keeping up of injection molding instruments can be costly and rolling out device improvements can be testing. The following are some plan tips to augment the advantages:

Consistency is ideal. Steady wall thicknesses all through your part will give the best stream. Typical wall thickness ought to be between 2-3mm. The least recommended is 1mm and the greatest is 4mm for customary plastic injection molded parts.

Smooth trumps sharp. Utilize radii when conceivable and stay away from sharp changes between wall segments.

Draft is your “frenemy.” Adding a draft edge to the faces of your part is useful to discharge it from the apparatus, yet it can cause configuration challenges particularly to parts that are meant to fit together. Recommend minimum draft angles are one degree on untextured center and no less than three degrees on textured faces.

Keep away from surfaces with zero draft unless it’s vital. In the event that you do require a zero-draft zone to guarantee appropriate part mating and resiliences, attempt to limit it to only a bit of the face, not the entire surface.

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Less complex is better. Stay away from undermines (territories that can’t be framed by means of the straightforward open/close bearing of a device). When simple won’t work, lifter and slides enable highlights to be formed that are undercuts in the main pull direction. Assuming this is the case, leave no less than 2 to 3 times the width of the component to enable the lifter or slide to movement.

Change from thick to thin. Parts will form better if plastic moves through highlights moving from more prominent to less wall thickness beginning from the gate(s) (where the plastic first streams in to fill the part).

Sink (a nearby surface mark on a section because of thicker segments of plastic cooling slowly) is awful. To diminish or kill the visibility of imperfections on restorative surfaces it is vital to take after some prescribed rules:

  • Try to maintain a strategic distance from entryways, ribs, screw bosses, etc. on the back side of important cosmetic surfaces;
  • Rib height ought to be 3x or less than the wall thickness;
  • Rib bases ought to be 60% or less of the wall thickness.

Datums define an area. Utilize datums (features that are utilized as reference focuses to characterize each part) to build up part interfaces and interactions to the general framework. Using a datum structure that matches the design intent of the assembly can mean the difference between a product functioning well or not.

Cross examination is great. Take DFM (Design for Manufacturing) reports truly since they pass on tool molder’s understanding of the design like ejector pin areas, gate areas and parting line area. Use inspection reports to interrogate the design.

Model early and frequently. Current prototyping strategies, including 3D printing takes into account early testing of outline ideas where bits of or potentially the entire part can be molded before building costly injection molding tooling.

Types of Plastic Blow and Injection Molding Part 2

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Types of Plastic Blow and Injection Molding Part 2

Injection stretch blow molding consolidates the injection molding and blow molding processes. The plastic is first formed into a strong preform, to make a threaded container neck. Once the preform cools it is encouraged into an extend blow form machine. The preform is then warmed utilizing an infrared radiator and blown into a plastic jug with constrained compacted air.

Injection molding and blow molding are two predominant procedures in plastic molding. Items made through these procedures are utilized as a part of an extensive variety of businesses, for example, car, food perp, hardware, medical gear, water system, dental, guns, energy and environment enterprises.

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The Blow Molding Process

Amid the blow molding process, the resin plastic material is molded into an empty tube with one open end called a parison. The parison is squeezed into a cooled metal form and packed air is blown into the parison. At the point when the shaped plastic cools and solidifies, the metal form opens and removes the item.

There are three kinds of blow forming forms:

Injection Blow Molding

In injection blow molding, a blow or center pole is utilized all through the procedure. To start with a parison is infused into a part form hole around the bar. The parison that is shaped seems to be like a test tube. The center bar transfers the parison to the blow mold machine where constrained air makes the last shape. The bar at that point exchanges and expels the completed item from the machine.

Extrusion Blow Molding

Extrusion blow molding can be constant or discontinuous. In consistent expulsion blow molding, a parison will be continually moved into the mold and each frame will be cut off with a cutting edge as it forms. Intermittent Extrusion blow molding ousts each new plastic from the metal form when it is cooled and the parison is put into the mold after the previous parison is removed.

Extrusion blow molds are for the most part significantly less costly than infusion blow molds and can be created in a considerably shorter timeframe. Extrusion blow molding is suitable for short runs.

Injection Stretch Blow Molding

Injection stretch blow molding consolidates the infusion molding and blow molding procedures. The plastic is first shaped into a strong preform, to make a threaded container neck.

Once the preform cools it is put into a stretch blow molding machine. The preform is then warmed utilizing an infrared warmer and blown into a plastic container with constrained packed air.

What Molding Processes Does Your Product Require?

What sort of assembling process is appropriate for your next venture? Our architects have many years of experience and comprehend what kind of material and form is appropriate for you. Get in touch with us to examine your new plastic design and we will walk you through the assembling procedure that is best for your task needs.

Types of Plastic Blow and Injection Molding Part 1

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Types of Plastic Blow and Injection Molding Part 1

Every plastic part requires a particular assembling process which can be quite unique one item to another. Injection molding is utilized to fabricate solid parts while blow forming is utilized to make plastic items with empty regions, for example, jugs and bottles.

Injection molding and blow forming are two main procedures in plastic assembling. Items made through these procedures are utilized as a part of an extensive variety of ventures, for example, car, food industries, gadgets, medical equipment, water systems, dental, guns, energy and environment enterprises.

To enable you to better comprehend the diverse assembling strategies accessible for your venture, we have put together a two section arrangement of the primary kinds of injection and blow molding methods used by plastics manufacturers.

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The Injection Molding Process

Injection molding is utilized to fabricate higher volume amounts of plastic items extending in estimates from huge parts to little segments requiring smaller scale exactness precision.

There are many kinds of assembling strategies ordered under injection molding, for example, thermoplastic injection molding, over molding, insert molding, cold runner molding and hot runner molding.

Thermoplastic Injection Molding

Thermoplastic injection molding utilizes thermoplastic polymer, which means it changes to a fluid state when warmed. Not at all like thermoset plastics that cool into perpetual strong, thermoplastics can be reheated to a liquid after cooling into a solid.

Overmolding

Overmolding, or two shot molding, is a procedure that covers an injection mold over another substance, for example, metal, to enhance the execution or strength of an item. An elastic like compound, called thermoplastic elastomer (TPE), is a utilized overmold material. A case of a TPE overmold application is the handles on a toothbrush. Overmolds can likewise be utilized to seal items with parts produced using a few injection molds.

Insert Molding

Like overmolding, insert molding is an injection molding process that joins at least two parts into a solitary completed item. Insert injection molding embeds a part into the injection mold and plastic material is filled around the insert. Inserts can add quality to an item and dispose of the requirement for extra parts to decrease the item weight.

Cold Runner Injection Molding

Cold runner molds utilize a sprue to fill the runners that infuse plastic resin into the mold. In 2 plate molds, the runner framework and parts are appended, and a discharge framework might be utilized to isolate the part from the mold. The cold runner can decrease waste by reusing and regrinding the material, yet this can likewise build the full process duration. Cold runner frameworks can be utilized for a wide assortment of polymers and can take into consideration simple shading changes.

Hot Runner Molds

Hot runner molds utilize a system to melt softened plastics and after that send the material through a door to fill the mold depression. The two principle sorts of hot runner molds are eternally heated and inside heated. The externally warmed molds can be utilized with polymer that is less touchy to warm while inside warmed hot runner molds take into consideration better control of material stream.

Since hot runner molding does not require the utilization of runners, potential waste material is reduced and the recycling and regrind and process of virgin plastic does not impact the total run cycle time.

In the next part we will go over the blow molding processes in plastic injection molding. If you have any questions feel free to give Quality Mold Shop a call or comment down below. Our engineers have decades of experience and understand what type of material and mold is right for you. Contact us to discuss your new plastic design or product idea today and we will walk you through the manufacturing process that is best for your project needs.

Most Common Thermoplastics Used in Injection Molding

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Most Common Thermoplastics Used in Injection Molding

Thermoplastic injection molding is the most well-known approach to make parts. Thermoplastics are polymers that can be heated to a liquid repeatedly or relaxed by warming and set by cooling—as a physical change as opposed to a chemical change that happens amid the formation of thermoset materials. It is imperative to recognize what sort of thermoplastic ought to be utilized for the kind of item you need to make. The following are the most widely recognized thermoplastics utilized as a part of injection molding.

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Acrylonitrile Butadiene Styrene

Acrylonitrile Butadiene Styrene (ABS), it is a dark thermoplastic and amorphous polymer. It is a terpolymer (copolymer comprising of three unmistakable monomers) of Acrylonitrile, Butadiene, and Styrene. Together they make an item that is adaptable and light in weight that can be shaped into numerous things that we use in our regular day to day existences.

The benefit of ABS is that an assortment of changes can be had to enhance impact protection, sturdiness, and heat protection. Molding at a high temperature enhances the gleam and heat protection of the item while molding at a low temperature is where the highest impact resistance and strength are obtained.

Polyethylene

Polyethylene is a thermoplastic polymer with variable crystalline structure and a huge scope of uses relying upon the type. It is a standout amongst the most adaptable and most famous plastics on the planet since the 1950s when it was produced by German and Italian researchers. The two most regular kinds of this plastic are high-thickness polyethylene (HDPE) and low-thickness polyethylene (LDPE).

The upsides of polyethylene are abnormal amounts of pliability, rigidity, impact protection, protection from dampness, and recyclability. The higher the thickness of the polyethylene material utilized the more grounded, more unbending, and more heat safe the plastic is. The essential employments of polyethylene are plastic sacks, plastic films, compartments including bottles, and geomembranes.

Polyamide (Nylon)

Nylon material is utilized as a part of a vast scope of various applications in view of its electrical properties, sturdiness, wear protection and chemical protection being very noteworthy. Nylon has an abnormal state of strength and is impervious to numerous outer components like scratches, impact, and chemicals. This material produces plastic parts utilized as a part of numerous businesses, for example,

  • Medicinal items
  • Car items
  • Games hardware
  • Attire and footwear
  • Industrial components

High Impact Polystyrene

High Impact Polystyrene (HIPS) is a prevalent and intense plastic that is in the Polystyrene family. Polystyrene is weak and can be more impact safe if joined with different materials. It is made from modifying crystal styrene with rubber which helps to give it many levels of impact resistance. It is low cost, has good dimensional stability and rigidity. There are FDA grades available since it is non-toxic and used as containers for many food goods.

It is exceptionally flammable, yet there are fire resistant and polished evaluations that are generally utilized for injection molding.

Polypropylene

This is an extremely regular plastic that is known for its adaptability. PP (polypropylene) is an exceptionally unique plastic and has been intensified for an extensive variety of properties. A few attributes of this plastic are its high liquefying point, high protection toward stress and splitting, magnificent impact quality, and does not break down from responses with water, acids, and cleansers.

PP is ok for use as food holders since it doesn’t filter chemicals into nourishment items. It can be generally found in family unit merchandise, for example, utensils, athletic clothing, area rugs, and car parts, for example, auto batteries.

Picking the correct material for your application can bring about expanded performance and decreased cost. At Quality Mold Shop, we comprehend that there is no “one size fits all” arrangement with regards to injection molded parts. If you have any inquiries or worries on what kind of plastic you ought to utilize, contact our group of specialists who can help you at all times.

Learn the benifits of replacing metals with plastics. Looking for a plastic molder?

Significant Advantages to Using Plastic Injection Molding for the Manufacturing of Parts

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Plastic injection molding is a great flexible technique for delivering parts and items. It is one of the favored techniques for assembling parts since it has various preferences over different strategies for plastic molding. Not exclusively is plastic injection molding less complex and more solid, it is additionally to a great degree more proficient. You ought to have no questions about utilizing this strategy to produce parts.

Plastic Injection Molding Process

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The plastic injection molding process is adaptable, making it versatile enough to produce anything from a simple plastic cup to car and laptops parts. While there are some alternatives to injection molding – like 3D printing and spin casting – injection molding remains the most reliable way to produce plastic goods. Because of this, injection molding is still the technique most often used to produce plastic goods in the 21st century.

But what is injection molding exactly? What does the typical injection molding process look like? And what exactly is it that makes injection molding so much more adaptable (and hence more versatile) than other options?

What Is Plastic Injection Molding?

Plastic injection molding is a technique used to shape plastic in the form of the object you’re aiming to produce. During the injection molding process, thermoplastic polymers are injected into a mold cavity. To do this, pellets of a material are heated so they can be injected into the cavity in a liquid state. This hot liquid is then left to cool in the mold so the part can properly set. Once one part is ejected from the mold, another cycle can promptly begin.

Although injection molding can also be used for metals and glass, it’s a particularly popular production process for manufacturing plastic parts.

The steps in an injection molding process cycle include clamping, injection, cooling and ejection.

During clamping, the injection mold is prepared for a cycle by tightly clamping the two halves that form the mold cavity into place. This ensures that the molded part will have a smooth appearance and ideally the molded part should have almost no line where the different halves came together, as this shows that the mold might not be clamping tightly enough.

Once the mold halves are clamped together, the mold is ready to form a part. Before the polymer is injected into the mold, the pellets are heated to form a liquid. The liquid polymer is then injected into the mold through a nozzle. This is the injection stage of molding process, which is the second stage in a four stage cycle.

Next, the part is left to cool in the mold for a predetermined amount of time. The cooling stage can take anywhere from a few seconds to a few minutes depending on the polymer being used to produce a part. While some polymers need hardly any time to cool at all, others can take a few minutes. It all depends on the part being produced.

Once a part has cooled, the injection mold is opened and the part is ejected from the mold. The mold will clamp again and prepare for its next cycle.

Because manufacturers know how long the cycle on their molds are, they can accurately predict the amount of parts a mold will produce every hour. This helps manufacturers know exactly how many parts they’ll be able to produce every day, week and month with a fully functional mold.

Why Is Plastic Injection Molding So Popular?

As mentioned above, plastic injection molding is a very predictable process. This predictability also makes the process dependable, as injection molding companies will know exactly how many parts they can expect from every mold they own.

Based on the amount of parts each mold is able to produce, manufacturers can calculate how many molds they need to in order to produce enough parts for their production line to operate at its intended capacity.

It should also be possible for manufacturers to estimate the amount of parts they can produce with a mold during its entire lifetime, making it easier to calculate whether or not a mold will generate enough income to cover its own costs with profit added.

All this is fine and well, but for injection molds to be reliable and predictable they must be maintained according to a maintenance schedule.

Unfortunately, some manufacturers run their molds till they break down. This might be because they’re just inherently stingy, but often times it was recommended to them by financial advisors in their company. The problem is that finance and engineering are worlds apart.

As mold manufacturers, we know that regular mold maintenance can extend the lifetime of your molds and help them operate optimally at all times. Yes, mold maintenance is an expense, but it’s not one you can cut to save money. If molding plastic parts is an integral part of your business, the condition of your molds in undoubtedly important. Cutting on maintenance by working molds till they break down will hurt your company.

It’s ironic that predictability, which is one of the advantages of injection molding, isn’t considered by many molders when overworking their molds. Fact is, a mold that works till it breaks down can’t always be repaired, and the halt in production from the broken mold can’t be scheduled because you won’t know for certain when it will break down.

When looking at it like that, it’s hard to understand why working a mold till it breaks could be considered a viable way to save money. Perhaps it’s time that molders look further into the issue of maintenance to establish what really works best.

But apart from the predictability of plastic injection molding, the process is also very versatile. Thousands of polymers can be used for injection molding purposes, and injection molds can be adapted for different uses. Which is why the process is as effective for the automotive industry as it is for the medical industry. With micro-molding technology, injection molding can even produce even very small parts with surprising accuracy.

To conclude, injection molding is popular mainly because no other manufacturing process allows manufacturers produce a lot of parts in a relatively short amount of time, all while maintaining the desired level of part integrity.

What are eco-plastics?

When thinking of plastic “ earth friendly” isn’t on the list. From trash pollution, to length of deterioration, to recycling; plastics aren’t normally in on the favorable side of the earth talk. If we could fix the problem at its source, what plastics are made of, we can make them more eco-friendly. But how something would last in a situation where the plastic is being used for long periods, and will be outside a lot in the weather such as automobiles?

Most of us have understood for years that plastic is an environmental no-no. It’s fuel based, requires lots of energy to produce and it clogs up landfills for what might as well be forever. It’s difficult to imagine a plastic we can buy without guilt. And whether eco-plastics fit that bill depends on how “green” you want to be.
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Can we ever replace plastic?

In our lives we are surrounded by plastics; phones, car parts, water bottles, food containers, computers, honestly almost everything has some form of plastic component. With almost everything we touch being made out of some form of plastic or another, it’s hard to imagine our lives without plastics. Will we ever be able to get rid of our plastic dependence?

The downsides to plastic are certainly no secret. For starters, it’s often a nonbiodegradable, petroleum-derived product. Factor in toxins, wildlife endangerment and difficult recycling, and the plastic industry has quite a public relations problem on its hands. But that’s only half the story.
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Identifying Unknown Plastics

Even if the plastic you have isn’t labeled which type of plastic it is (though it should) there is ways to tell what type you have. Though the variety of possible plastic materials is essentially infinite, the familiar SPI recycling codes are the typical way to identify plastics. Knowing what plastics are used in other projects can help you find the plastic you are looking for in your own project.

The burn test, as it’s known, correlates a plastic sample’s composition with a set of observable properties including…
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