Product News
An Introduction to Injection Processing
An Introduction to Injection Processing
Injection processing is one of the most common methods for manufacturing plastic parts, with an incredible variety of products being produced by this method. The process involves an injection molding machine, raw plastic material and a mold that is injected with the melted material to form a part. It is a highly complex process that relies on accurate control of several factors, including temperature and pressure.
A good understanding of injection processing can help to improve the quality and reliability of plastic parts, reduce costs and increase productivity. This article will explore the key aspects of injection processing and some of the most important factors that need to be taken into consideration in order to achieve a high level of consistency and quality in injection molding.
Getting started with injection molding
The first step in the process of injection processing is to design the part that will be fabricated using an injection molding machine. Then the tooling, which is a metal block of aluminium or steel, must be CNC milled to create the negative of the plastic part’s shape. After the mold has been fabricated it is ready to be used in the injection molding process. The tooling is inserted into the injection molding machine and hydraulically clamped together to keep it securely closed as the plastic is injected and cooled. Once the process is complete, the mould is ejected by an ejection system and the solidified plastic is removed from the mould.
Various types of injection processing machines are available depending on the size and complexity of the part to be manufactured. Screw injection machines are commonly used for smaller and simpler parts, while rotary injection machines are usually used for larger and more complex parts. The type of machine selected depends on the material, the application and the production volume required.
Injection processing and temperatures
A great deal of energy is used in the injection molding process, and therefore it is crucial to manage the melting temperature carefully. Temperature measurement and control are essential to the injection molding process as the temperature of the polymer determines the rate at which it melts. It is also critical to maintain an even temperature throughout the injection process, as fluctuations can result in inconsistent results.
An injection molding machine is typically operated at a temperature between 300 and 800 degrees Fahrenheit (149 and 426 degrees Celsius). This is the temperature at which a thermoplastic melts and flows. A low melt temperature will not adequately liquefy the polymer, while a high temperature can cause it to burn.
Injection molding is an excellent technique for producing parts with complex geometries that are difficult or impossible to manufacture by other means. However, the complexity of a part’s geometry can influence the final outcome and can result in defects like knit lines. Knit lines are formed when 2 separate flows of molten plastic meet, and they can affect the cosmetics of a part as well as its strength.
0users like this.
