High Volume Injection Molding

Inox Cast – Leading Manufacturer of High Volume Injection Molding

Inox Cast is the best manufacturer of high-volume injection molding in China. It has awesome surface finishes and a robust structure. Unique polished, high-quality textures and EDM marks.

Inox Cast has the widest range of high-volume injection molding that is made from premium metal, PVC, PET, high-grade materials, PP, etc. We provide the best high-volume injection molding for different applications such as automotive, appliances, household products, and other commercial products.

Our high-volume injection molding can be purchased in custom models, production capabilities, and sizes. You can also give your ideas and we will make it done for you. Moreover, Inox Cast used the latest ideas to develop high-volume injection molding that exceeds your expectations.

Inox Cast high volume injection molding produces world-class products that will surely hit your market. We want to help you build a business empire in this industry. Our high-volume injection molding is available for both OEM and ODM.

Our professional engineers always come up with new ways to enhance or improve our high-volume injection molding and other equipment into more advance and aggressive machines.

We can guarantee you that our high volume injection molding is made from high technology machines operated by highly skilled workers. Inox Cast wants to offer you the best result for your production.

Since 1997, Inox Cast earned trust and good feedback from customers worldwide. Our main goal is to help you find high-volume injection molding and other equipment that is developed and handled by professionals.

Inox Cast’s main goal is to be your most reliable high-volume injection molding manufacture. We can give you the best deals that will surely fit your budget.

You can check on us anytime! We are available 24/7 and willing to help you find your ideal high-volume injection molding.

High Volume Injection Molding: The Ultimate Guide

Today’s guide focuses on vital aspects of high volume injection molding process.

Whether you want to learn about various techniques, benefits, productivity or considerations – you will find all information right here.

So, keep reading to learn more.

1.  What Is High Volume Injection Molding?

High volume injection molding is the process by which advanced and experienced machinery is used to manufacture industrial grade and ready to integrate products.

Raw plastic is injected using an injection mechanism into a mold that shapes the molten plastics. Mold is opened with the help of a clamp that ejects the parts.

High volume injection molding is applied in many industries that use plastic parts as an integral part of any product.

high volume injection molding

A high-volume injection process was invented in the 20^th century to aid in the mass production of plastic items.

The process has been streamlined and made more efficient using robotics and automation.

Mold design files and CAD entirely 3D part design are sent to the manufacturing plant, and plastic molds are then created.

2.  High Volume Injection Molding Vs. Low Volume Injection Molding

A good number of plastic parts and products are created through a manufacturing process called injection molding.

When planning for an injection molding process, it is vital to consider factors such as volume.

Production volume is divided into three: high-volume, mid-volume, and low-volume.

low volume injection molding

The following are the differences between high-volume injection molding and low-volume injection molding:

Low-volume injection molding

Depending on the method used, it involves less than 10,000 pieces of the component. The tooling used is made from Aluminium.

Entry To The Market Is More Accessible.

Low-volume injection molding involves shorter turnaround times and low initial costs; thus, small and new companies with a small budget can still produce parts and products.

Design Flexibility Is More Significant.

New molds are readily created to change the component’s design because low-volume injection molding has lower costs, and tooling can be done at high speeds.

Tooling Costs Are Lower, And Shorter Turnaround Times

The tooling used is made from aluminum which is cheaper and easier to manufacture.

Applications of low-volume injection molding

Low Concentration Production Runs

Low-volume injection molding is the best choice for molding projects that require less production.

Prototyping

The lower costs and high production speed of low-volume injection molding make it the best prototyping choice.

Production Of The Pilot And Testing Of The Marketing Trial

It is best used for creating pieces for testing the market.

The high volume injection process involves the production of many pieces; mass production.

The tooling used is made from hardened steel.

Unit Costs Are Lower.

Before replacement is required of the hardened steel molds, more pieces are created because of their durability.

Therefore, overall unit costs can result in being lower.

Greater Capacities At Higher Speeds

Millions of pieces can be made at a time using a high-volume injection molding process.

Is The Best Fit For Automation

Automation will lower unit costs and increase the capacity of production.

Applications of High-volume injection molding

Production Of Standardized Products

It is best to produce large quantities of standardized products because costs are kept low while allowing for high quality and consistency.

Contract Manufacturing

They are commonly used in contract manufacturing because they have the essential features to handle the jobs efficiently and faster.

Major Manufacturing

Best used when a high volume of production is needed.

3.  High Volume Injection Molding Vs. Mid-volume Injection Molding

The high volume injection process involves the production of many pieces; mass production.

The tooling used is made from hardened steel.

Unit Costs Are Lower.

Before replacement is required of the hardened steel molds, more pieces are created because of their durability.

Therefore, overall unit costs can result in being lower.

Greater Capacities At Higher Speeds

Millions of pieces can be made at a time using a high-volume injection molding process.

Is Best Suitable For Automation

The high-volume injection process is best suited for automation. Automation will lower unit costs and increase the capacity of production.

High-volume injection molding is commonly applied in the following areas:

Production Of Standardized Products

It is best to produce large quantities of standardized products because costs are kept low while allowing for high quality and consistency.

Contract Manufacturing

It is commonly used in contract manufacturing because it has the critical features to handle the jobs efficiently and faster.

Major Manufacturing

Best used when a high volume of production is needed.

Mid-volume injection molding involved volume production between high and low volume production.

The volume ranges between a hundred thousand products and a few thousand.

As compared to high-volume injection molding, it has lower costs.

It also has a shorter lead time as compared to high-volume injection molding.

mid volume injection molding

4.  Benefits Of High Volume Injection Molding

Some of the benefits of high volume injection molding are as follows:

Unit Costs Are Lower

Before replacement is required of the hardened steel molds, more pieces are created because of their durability.

Therefore, overall unit costs can result being lower.

Greater Capacities At Higher Speeds

Millions of pieces can be made at a time using a high-volume injection molding process.

Is Best Suitable For Automation

The high-volume injection process is best suited for automation. Automation will lower unit costs and increase the capacity of production.

• High-quality, accurate, and consistent mass production of parts
• Large volumes are produced at a higher speed.

5.  Choosing High Volume Injection Molding Machine

The following are the factors to be considered in the high-volume injection molding machine process:

Plastic Parts That Are Intended To Be Mold Are Identified And Known

Knowing the specific details that the machine will mold is the first thing in machine selection.

If parts that are not best suited for the machine are molded, it can lead to defects, mold and machine damage, slow cycle times, and quality problems.

The following are the part factors that to should consider:

• Gate location
• Mold weight and size
• Material
• Length, width, and height
• Average wall location
• Quality requirements
• Estimated cycle time
• Annual quantity time
• Selecting machine type

The following are the types of machines:

Hybrid

A hybrid injection molding machine integrates both electric and hydraulic devices.

When molding thin wall parts, a hydraulic machine produces fast injection speeds while the rest uses electric drive servo motors.

Fully Hydraulic

Hydraulic machines are defined by the absence or presence of an accumulator, hydraulic pump design, and clamp design type.

Hydraulic pump design can be a variable displacement pump, a servo pump, or a constant displacement pump.

It can be by hydraulic ram or a toggle clamp when it comes to clamping design.

For parts with a wall thickness of 0.3mm to 0.8mm, accumulators are needed to mold them.

Some machine manufacturers use accumulator presence to drive the entire machine, and others use it in the injection stage.

Factors to consider before choosing a hydraulic molding machine:

• Energy efficiency
• Mold design
• Part design
• Cycle time requirement
• Hold time requirement
• The used or new machine
• Price of purchase
• Cleanroom requirement
• Material to be processed
• Fully electric

Entirely electric machines are suitable for cleanroom operations as compared to hydraulic oil.

Electric machines guarantee consistency in part quality as they have perfect repeatability and are energy efficient.

Clamp Tonnage Requirement Calculation

Clamp tonnage requirements are calculated in the following ways:

• Computer simulation software
• My experience
• Easy calculation as an outline

Projected Area X Average Cavity Pressure X Number of Cavities

Calculating tonnage using the simple calculation requires the following part information:

• Length, width, and height
• Material
• Gate location
• Average wall section
• Number of cavities in the mold
• Distance from the gate (maximum)

The Injection Unit Size Calculation

The following are the factors to consider about the part when choosing the suitable unit for the high-volume injection molding machine:

• Cycle time
• Material
• Injection rate
• Cooling time
• Hold time
• Weight and number of cavities

Two injection units are offered to choose from by manufacturers for a specific tonnage machine.

The units have barrel assemblies and three variety screw-on offers.

Choose the proper assembly, and the shot size must be calculated as a percentage of the injection capacity.

high volume injection molding machine

 Production of good quality parts must lie between 25% and 65%.

Melt density needs to be known when calculating the shot capacity for screw and barrel assemblies because they are rated in grams of GPPS (general purpose polystyrene)

6.  How To Increase Productivity In Injection Molding

A few changes are made to bring positive results by increasing productivity in injection molding.

The following are how productivity in injection molding can be increased:

Scrap Reduction

Because scrape is a critical element of production rate and labor expenditure, it needs to be monitored closely to reduce the costs of covering the loss.

Conservation Of Mold Preventative

To prevent mold maintenance costs, if injection mold breaks down, then molding is stopped and attended to when not in use or during downtime.

Shorter Setup Times

While other jobs are running, it is vital to have a different mold machine to set up appointments.

Therefore, it ensures that the process continues when jobs are set up, increasing production.

Keeping Track Of Production Rates

It is crucial to monitor the production regarding the number of employees employed and their rates and develop ideas and solutions to reward them.

Rewarding employees in terms of the excellent work done will result in high returns in production.

Expansion Of Molding Activities

Expanding molding activities means ensuring the injection molding experts have the best training.

Automating the production is also an excellent solution to increase productivity as it will save on time and labor.

Optimum Run Size First.

Each minute gets less expensive when the injection molding machine is constantly running without defects.

7.  Factors Determining Cost Of High Volume Injection Molding

The following are some of the factors determining the cost of high volume injection molding:

1. Location of the mold manufacturing
2. Volume and cavities
3. Design of the part
4. The material used to make the mold
5. Part material used

8.  High Volume Injection Molding Techniques

Focus on various injection molding processes/techniques/types or classification

Define each process/advantage and when to choose the technique

High-volume injection molding techniques are mainly classified based on the type of material used as a mold and the size of the parts.

Some of the types of high-volume injection molding processes include:

Micro Injection Molding

This injection molding process manufactures plastic parts of short weights ranging from 1 to 0.1 grams with tolerances ranging from 10 to 100 microns.

Manufacture of small complex geometries is therefore offered with maximum precision and accuracy.

A microinjection unit is integrated into the injection molding machine with the microinjection molding process.

The following are factors to be considered by the process technology and machine when producing micro components.

1. Accuracy of dimensions
2. Dwelling time should be short
3. Low shear stress on the polymer melt
4. Preparation of the material before molding
5. Injection and ejection precision

Complicated factors in the microinjection molding process are:

Dating Issue

The smaller size part causes issues with gate removal; dating

Parting Line Issue

Line of separation in the region where two halves of the mold meet are referred to as a parting line.

Parting lines can be an issue in the microinjection molding process; thus, core for precise mating and the interlocking features of mold cavities are used to minimize the problem.

Spruce And Runner Size

The size of the sprue and runner is also an issue in micro injection molding.

The volume of the parts can be exceeded by the total volume of sprue, gate, and runner by 100 or more.

Gas-assisted Injection Molding

Gas-assisted injection molding process involves a plastic melt pushed into the mold at the end of the polymer stage by an inert gas at pressure.

Advantages

• Low clamp force
• Thick parts can be molded
• There are no sink marks
• Products are light-weight
• Part deformation is reduced

Disadvantages

• Plastic materials are an exception to this method
• The method is challenging for the production of multi-cavity mold.
• Thin-wall injection molding

Type of injection molding process that involves large-scale production of plastic parts that are light and thin.

It saves on material costs and ensures short cycle times; higher productivity.

Thin-wall injection molding process focuses on the size of the part rather than its wall thickness.

Advantages of a thin-wall injection molding process

• Fast cycle times
• Produces safe, lean, and cheap parts
• Parts can be manufactured from recyclable plastic
• The molding process reduces fuel usage and cuts weight and other resource consumption.

Limitations of a thin-wall injection molding process

• Injection molders can be pretty expensive; hence high capital investment cost
• Highly skilled experts are required for the thin-wall injection molding process, which is hard to find and maintain
• Leads to environmental litter

Applications of a thin-wall injection molding process

• Mobile telecommunications
• Automotive industries
• Computing equipment
• Medical and packing of food
• Reaction injection molding

Type of injection molding in which two parts of polymer are mixed into an impinging mixer by injecting them under high pressure.

Therefore, under low pressure, the mixture is injected into a mold. For the medicine to expand and cure, it is then let sit in the mold for quite some time.

Benefits

• Low capital expenditure as the thin mixture requires less clamping forces
• With a low-density core, a high-density skin is formed
• Light-weight, strong and flexible parts are produced and can be painted
• Fast cycle times

Limitations

• Raw materials are costly
• Compared to injection molding, it has slow cycle times

Die casting

Die casting involves a molten metal forced under high pressure into a mold cavity.

Hardened tool steel dies shaped through the machine are used to create the mold cavity.

Many die castings are made using lead, steel, aluminum, zinc, and copper, and hot-chamber or cold-chamber machines are used depending on the metal type being cast.

Features to be considered when creating a model for die casting:

• Fillet
• Bosses
• Parting line
• Draft
• Ribs
• Holes and windows

Advantages of die casting

• Production rates are of high-speed
• Dimensional accuracy is excellent
• Inserts can be cast-in
• It gives a smooth cast surface
• Due to the smoother surface, corrosion rates are slower than sand castings.

Disadvantages of die casting

• Die casting is limited to high-fluidity metals
• A large number of parts are involved in die casting; hence repeatability
• Die casting is limited to features that only require a soft surface and no hardening
• Injection molding of liquid silicone rubber

Injection molding of liquid silicone rubber is an injection molding process that involves high-volume parts being produced.

The high-volume parts are durable and flexible.

The processes use the liquid silicone rubber to produce high-quality parts because it has excellent stability, a low compression set, and can withstand cold and hot temperatures.

Advantages of injection molding of liquid silicone rubber

• Cycle times are short
• Repeatability of the process
• It is an automated process
• Injection is direct
• Demolding systems are automated

9.  Applications Of High Volume Injection Molding

High-volume injection molding is commonly applied in the following areas:

Production Of Standardized Products

It is best to produce large quantities of standardized products because costs are kept low while allowing for high quality and consistency.

Contract Manufacturing

They are commonly used in contract manufacturing because they have the critical features that will handle the jobs efficiently and faster.

Major Manufacturing

Best used when a high volume of production is needed.

10.  Choosing Mold For High Volume Injection Molding

Before choosing the suitable mold for high volume injection molding, the following are the factors to be put in place:

1. Quantity of parts to be produced
2. Project development stage
3. Complexity or geometry of parts
4. The initial cost of mold build
5. Speed to build

high volume injection mold

11.  Critical Considerations During High Volume Injection Molding

The following are the key considerations during high-volume injection molding:

Quantity Of Production

The quantity of parts to be manufactured is a crucial factor when choosing high-volume injection molding.

It will help decide if high-volume injection molding is cost-effective.

Design Factors

Choosing the design of the mold tool is critical as it will help avoid mistakes during production.

High-volume injection molding will be made more accessible if the number of parts to be manufactured is minimized and geometry is simplified.

Financial Costs

The initial costs of high-volume injection molding are pretty high because of the machinery and mold costs.

Production Considerations

When choosing a high-volume injection molding process, there must be production considerations.

Production is aided by minimizing the cycle time by using hot runner molds and tooling machines.

It will also reduce costs.

12.  What Is Precision Injection Molding?

Precision injection molding is an injection molding type in which the conventional molding process and injection molding requirements are hard to meet.

The precision injection molding process uses plastic parts to replace high-precision metal parts in the instrument and electronics field.

precision injection molding

This is instead of the conventional injection molding process.

Precision injection products have two definition targets:

• Repeatable precision of the product quality
• Repetition precision of the product size

Properties of precision injection molding

The following factors characterize precision injection molding:

• Parts have high precision size limits; have small tolerances, and high precision.
• A precision injection machine is embraced to replace the conventional injection machine.
• A precision injection molding process is accepted.
• The material used for mold is rigid and good.

Factors to consider for precision injection molding:

1. Mold design
2. Selection of material
3. The technology level of the operator
4. Injection molding process

Injection molding machine requirements include:

1. Products with 0.01-0.001mm
2. High injection pressure
3. High-speed requirements
4. High position precision mold; flow temperature, pressure requirements

Types of materials used in the everyday use of precision injection molding are:

PC And GFPC

It has the following features:

• Good molding
• Wear resistance is good
• Dimensional stability is quite good
• Rigidity is enhanced

PA And Glass Fiber Reinforced PA66

This type of material has the following features:

• Performance flow is good
• Wall thickness products are formed up to 0.4mm
• Wear and impact resistance is strong

POM And Carbon Fiber Reinforced

This type of material has the following characteristics:

• Fatigue resistance
• Weather ability
• Dielectric properties are good
• Creep resistance is good
• Burning is complex, and lubricant can be released easily

PBT Reinforced Polyester With A Short Molding Time

Precision injection molding has a shrinkage problem. The following are the factors that affect the shrinkage problem:

1. Orientation contraction
2. Heat contraction
3. Compression contraction
4. Phase change contraction

More Resources:

Injection Molding Process

Short Run Injection Molding

Small Scale Injection Molding

Prototype Injection Molding

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