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Injection Molding: Technology Overview, Advantages and Disadvantages

Injection Molding: Technology Overview, Advantages and Disadvantages

 Estimated reading time: 4 minutes, 20 seconds

injection molding machine

Injection Molding Machine,Source from:wilimedia

What is injection molding?

Injection molding is a manufacturing process that produces parts by injecting melted material into a mold. Injection molding can be done with a variety of materials, most commonly thermoplastic and thermoset polymers. The part material is fed into a heated barrel, mixed (using a screw screw), and then injected into a mold cavity where it cools and hardens into the shape of the cavity. After the product is designed, usually by an industrial designer or engineer, it is made of metal by a mold maker and precision machined to form the shape of the desired part. Injection molding is widely used to make a variety of parts, from the smallest component to the entire body panel of an automobile.

 

Industry Application

 

What are the advantages of injection molding?

Very high efficiency

The injection molding process is very fast. The molten thermoplastic cools quickly in the metal mold and the time between cycles can be as short as 20 seconds, making the process efficient and cost effective.

The machine can also run 24/7, which reduces total production time.

 

Impeccable accuracy

component injection molding

Because of the method in which the material is injected into the mold and then molded by the mold, the number of defects can be reduced to a minimum.

As you can imagine, this precision is important in almost all industries, especially in those that cannot compromise on quality, which is why injection molding is so popular in demanding fields such as aerospace and automotive.

Intricate details

Although certain design principles must be followed, injection molds can be made into a variety of complex shapes, allowing for the manufacture of intricate plastic parts.

You can add multiple details to the mold design and rest assured that each detail will come to life with the mold.

 

Durability

Unlike most other production methods, injection molding offers advanced possibilities in terms of the durability and reliability of the plastic parts produced.

For example, you can add fillers to the injection molds you create, which helps reduce the density of the plastic material and makes each part stronger.

 

Automation

One of the main reasons for the high consistency of parts using injection molding processes is that many of the actual manufacturing processes can be automated.

This means that the potential for human error can be minimized, and it also allows machines to produce at a manageable rate for effective lead time control.

 

Cost-effectiveness

In most cases, injection molding is one of the most cost effective solutions you can find for producing parts. Although the initial processing cost of injection molding is high. Because metal molds must be manufactured using processes such as CNC machining or metal additive manufacturing, which require significant material and labor costs, the cost per unit for injection molded parts can be very low as the number of parts produced increases.

 

Wide range of raw material and color options

ABS injection molding

The injection molding process is quite compatible with many different plastics. You can choose from plastics, thermoplastic rubbers, chemically resistant plastics, biodegradable plastics, and many others. Plastics can be selected based on several factors, including tensile and impact strength, flexibility, and heat resistance.

Injection molded parts are also easy to color, which is one of the reasons the process is so widely used in consumer products. You can also choose from almost any color imaginable, as well as from a wide range of finishes, whether for aesthetic or functional purposes.

What are the disadvantages of injection molding?

Now that we understand why injection molding is so effective, let’s take a look at some of its disadvantages to provide you with a more comprehensive picture.

As a processing technology, injection molding has good advantages in terms of productivity, precision, and raw material selection, but we can’t expect one process to cover all design needs. So, let’s take a look at some of its disadvantages and production limitations in order to provide you with process references for your product design.

 

High initial cost of mold

Although the unit cost of injection molded parts can be achieved very low. However, as we mentioned before, before the actual manufacturing, you need to design the mold and make the mold, and the mold cost should not be underestimated. Good design and effective cooperation from the manufacturer are crucial, so we recommend you to use Prolean’s injection molding service. You can always contact our engineers for a consultation and quote.

molding injection molding

Design Size

While injection molding machines can produce fairly large parts up to about 60 cubic inches, if you need a larger part, you may have to choose another manufacturing method, such as plastic fabrication.

Nonetheless, in most cases, your part will most likely fit the parameters perfectly, so you should be fine.

 

Delivery Time

This is because the actual production process of injection molding takes place after the mold production is complete. Mass manufacturing cannot take place during the design and manufacturing phase of the mold. Therefore, it can be more time consuming than some other processes. At least in smaller volumes.

 

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Injection molding is widely used in various industries and can achieve seamless and precise mass production of parts in a short period of time. Prolean Tech offers injection molding services for dozens of materials, including plastics and elastomers. Simply upload your CAD file for a quick, free quote and consultation on related services.


Post time: Apr-01-2022

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