Injection Molding

Inox Injection Molding

Inox Cast is your authentic injection molding service and solution provider with wide experience in this industry. Due to our full dedication to the excellent efforts, we can additionally provide top-quality, advanced, and accurate injection molding molds and constant customer service.

Inox Cast is an expert in the injection moulding process for manufacturing parts by injecting molten material into a mold or mould. This process can be performed with a metal material, glasses, confection, thermosetting and thermoplastic polymers.

However, this is broadly used for producing a variety of components, from the smallest parts to entire body panels of cars. This injection moulding works to create various things including packaging, wire spools, automotive components, parts, pocket combs, small tables, one-piece chairs, musical instruments, and so on.

The injection moulding uses special-basis equipment that has 3 parts like the clamp, the mould, the injection unit. The final injection-molded components are carefully structured to ease the moulding process. Through this process, you can achieve the desired features and shapes of parts you want for your application.

Inox Cast conducts injection moulding is an effective process to get molded products. The finished products are commonly used in some industries including manufacturing equipment, medical components, devices, and many more.

For many years in this field, you can totally rely upon Inox Cast. We can be your perfect partner in terms of providing reliable injection molding services.

This cost-effective process will bring you numerous advantages for your business. You will save cost and efforts by preferring our injection-molded products.

Why choose Inox Cast for your injection molding requirements? The main reason is we have the ability to custom injection molding based on your own specifications. Our company is also composed of qualified technical skills, advanced machines, and professional customer assistance. All in all, we can guarantee a safer, precise, and on-time shipment of your orders.

Message us if you need more details regarding Inox Cast expertise.

Injection Molding: The Ultimate FAQ Guide

If you have any question on injection molding, you will find the answer right here.

Whether you want to learn about injection molding process, benefits, parts or material type – you will find all information in this guide.

Keep reading to learn more.

1. What Is Injection Molding?

Injection Molding is a process of manufacture used in the production of large volume of parts by having molten materials into Molds.

The items are mass produced and they are identical in their form and property.

injection molding

2. What Is The Process Of Injection Molding?

The mold is first created using a metal normally aluminum or steel and machined with precision to match the part product.

The molten material from the part is then placed mixed with a helical screw shape inside a heated barrel.

The material is heated using heating bands and the molten material injected into the mold cavity and allowed to cool and harden.

The hardened molten material takes the shape of the mold with cooling lines circulating oil or water from an external source.

Once the part has solidified, the mold is opened using mold tools attached to plate molds.

3. How Does Injection Molding Compare To Die Casting?

Die casting is considered more or less a basic process of Molding but requiring use of less complicated technology.

The plastic is heated to molten form and placed inside a mold, left to cool and eventually removed.

The low pressure used in die casting produces intricate shapes and sizes while Injection Molding produces 3D objects.

injection molding

 They are usually very high quality and can be reproduced commercially and in large numbers.

The plastic is initially melted in a hopper and injected into mold that is tightly closed and takes its shape after cooling.

The mold id then opened after the plastic cools and the plastic ejected.

Die casting

4. How Doe Hot Runner Injection Molding Compare To Cold Runner Injection Molding?

Hot Runner Injection Molds contains a conduit that is heated to inject molten plastic into the mold cavity.

hot runner injection molding

For the cold runner, the physical conduit is unheated and the runner does not form part of the injection mold.

cold runner injection molding

5. What Are The Different Types Of Injection Molding Technology?

The following Injection Molding Technologies are assisting companies to rapidly and efficiently produce more parts:

Thin Wall Molding

This is an Injection Molding Technique that results in the formation of a plastic part having a very thin wall.

Most of these parts are used in applications like test apparatuses, tubes, electronic components and various enclosures.

thin wall molding

Liquid Silicone Injection Molding

In most Plastic Injection Molding, a mold that is extremely hot has colder material injected to form a part.

The thermoset process ensures that the part is cured enough to avoid further melting.

liquid silicone injection molding

However, thermoplastic Injection Molding produces parts that tolerate chemical agents and extreme temperatures like car parts.

The liquid commonly used is liquid silicone.

Gas Assisted Injection Molding

The major challenge facing parts that are thick and injection Molded is the distortion they undergo when cooling.

When gas is shot into the injection mold filled with plastic, it ensures the inside is hollow and porous.

Gas assisted injection molding

The plastic outside the mold will have a smooth finish look.

In addition to preventing deformation during cooling, it also lowers the part cost by utilizing fewer material.

Metal Injection Molding

Metal can as well be injection Molded in as much as plastic is the common material used.

This advanced technology is more expensive compared to plastic with a specific niche market served.

The Mobile phone market utilizes metal injection molding to buffer cellular devices form radio microwaves.

metal injection molding

3D Printing

This technology has assisted Injection Molding greatly because of prototyping of injection molded part before production.

This enables potential adjustments to be carried out ineptly.

Actual Injection Molds can also be printed by either plastic or metal using a 3D Printer.

3D printing

6.      What Are The Factors Affecting Injection Molding?

There are several very critical factors that influence the Injection Molding Process:

Plastic Melt Temperatures

This is a combination of different settings and factors that include mold, nozzle and barrel temperatures.

Barrel and flow temperatures affect the plastics flowability and plasticizing while inside the mold.

Barrel Temperatures

Careful consideration has to be given to barrel temperatures to vary between the thermos-decomposition and melting point temperatures.

Flash and overflow may occur if it is too high and ripples, empty parts and melt lines occur when it is too low.

Cooling Rate and Timing

The difference between the mold temperatures and melt temperatures bring the variation in cooling rates.

Fine tuning the cooling rate and timing will depend on the requested part size, the required properties and appearance of the part.

Plastic Flow Rate

The heated plastics capacity to be quickly injected into a cavity to near fill has to be supported by the plastic flow rate.

They determine viscosity as plastic is injected into the mold cavity with overflow and flash being high with high viscosity.

Nozzle Temperature

Nozzle temperatures should be low compared to barrel temperatures to avoid drooling of plastic in the nozzle.

If the temperatures get too low, the plastic will decompose and block the nozzle causing bad components.

Plastic/Screw back Pressure

They are regulated using controlled relief valves found on the Injection Molds hydraulic system. A high pressure increases the plastics flowability thus causing flashes and overflows while low pressures reduce flow causing voids and bubbles.

7. What Are The Factors To Consider When Choosing An Injection Molding Company?

Injection Molding Process contains minute details with precision a key factor in its success.

This means that the Injection Molding Company has to be efficient and cover the clients need and they budget allocations.

The factors to consider while sourcing for a Molding Injection Company include:

Great Design Team

Since design is the most crucial aspect of a molded part, a great design team ensures that the final results are exemplary.

Clear design concepts ensure an efficient production process thus saving time and costs.

Time Considerations

Since time is very important in any process, it is vital for various time taking steps to be factored in.

They include the part complexity, any design revisions or the time taken for design discussions with the team.

Unexpected delays should be accounted for like shipping delays or unavailability of resins for the plastic.

It is important to discuss one’s time expectations with the chosen injection Molding company prior to production.

Production Capacity and Volume

The size of the production requirements should be used to narrow down on the intended production company.

Molders specialize in various production capacities like low, moderate and high.

Quality Assurance

A good Injection Molding Company should have an efficient in-house quality assurance team to observe production.

The machines should also be of high quality, good mold maintenance practices and inspection processes implemented.

Complete Range of Services

It is important to go for an Injection Molding company offering one stop manufacturing solutions.

Services like prior consultations from concept and design stages assist in attaining optimal designs meeting budget needs.

Other services like prototyping, technical requirements on production, mold flow analysis and part design are added advantages.

These are offered beyond the usual services offered by other Injection Molding Companies.

Available Technology And Specifications

Sometimes the specifications of certain injection Molded parts end up being compromised due to poor technology.

The available technology level of the company should be assessed first and their experience and knowledge in applying them.

Product Application

The intended part application also plays a major role in deciding an injection Molding company based on components.

The company should offer a detailed guide of available plastic resins determined by your parts end use.

8. What Should You Consider When Choosing Injection Molding Machines?

There are several considerations to keep in mind while sourcing for in Injection Molding Machine. They include:

Financial Cost

The cost of beginning an Injection Molding is always made very high by how much the machine will cost.

The molds themselves too will affect the cost based on their complexity.

Production Quantity

It is crucial to have a definite number of parts that are going to be manufactured.

This assists in determining the kind of Injection Molding machine that is appropriate and cost effective.

Production Consideration

When the cycle time is reduced, the production will improve the same way as using hot runner Mold machines.

Using machines with efficient thought-out tooling can increase savings used in parts.

Design Factors

Having a minimal number of parts with a simple geometry can help in settling on a cost friendly Injection Molding machine.

The reduced complexity and mold design also reduce post production defects.

9. What Are The Considerations When Undertaking Injection Molding?

These are some tips needed to be considered before beginning an Injection Mold Project:

Mold Classification

Mold guidelines have different classifications based on the region of manufacture.

Depending on the project details, the classifications and guidelines will have a direct impact on the mold cost.

Resin Type

Choosing the right type of resin from the thousands available for your application is very critical. The purpose of the molded part and its entire component has to be considered for traits such as abrasion, chemical or other resistances.

Whether they are to be used in high-impact applications or contain fluids are other considerations.

All these will determine the choice of the most appropriate resin to be used.

Mold Flow Analysis

After confirming the mold classification and the resin to be used, the mold should be analyzed during injection for resin flow.

The Design for Manufacture (DFM) step should include the mold flow analysis.

Surface Finish

Deciding on the best surface finish for parts requires consultation with Injection Molding expert for the desired results.

The finish may also serve as cosmetic role or be part of the designs functional component.

Available Budget

Some factors that define the budget are the design and part application, and the mold classification.

Complex designs with intricate features will cost more in addition to the number of parts required.

Project Lead Time

A general schedule guideline should be prepared at the beginning based on the budget, specifications and available personnel.

If the Injection Molding needs to be done faster, then the cost will increase.

10. What Are The Advantages Of Hybrid Injection Molding Machines?

The Hybrid Injection Molding machines combine the benefits of both hydraulics and Electric Motors. Its advantages include:

i) Best of Both: this machines brings together the hydraulic unit’s capacity to generate force and the accuracy and energy saving of electric molds.

ii) Diversity: the combination of the two dynamics has made design flexibilities reach new uncharted degrees.

iii) Reduced Downtime: maintenance is drastically reduced hence a lower downtime compared to a fully electric or hydraulic machine.

iv) Replaced Motor: variable-speed AC drives have replaced the fixed-speed DC motors so it only operated when needed.

This improves process efficiency by using only the required oil.

hybrid injection molding machine

11. What Are The Different Plastics Used In Injection Molding?

There is a very wide variety of commercial plastics and polymer families that are used in Injections Molding. The common ones include:

• Acrylonitrile Butadiene Styrene (ABS) – it has a high impact resistance and very strong.

It has very good dimensional stability with low rates of shrinkage and resistance to acids and bases.

• Polyetherimide (PEI) – also called Ultem, it has good retardancy to flames with a resistance to temperature.

Its chemical resistance and strength are excellent in addition to its dimensional stability.

• Polycarbonate (PC) – this is a strong transparent plastic with impeccable dimensional stability and low shrinkage.

With a good cosmetic finish, they have different clear optical grades having a good resistance to heat.

• Polyether Ether Ketone (PEEK) – with good flame retardancy and resistance to heat, this high performance resin can withstand high temperatures.

It also has good chemical resistance with dimensional stability.

• Aliphatic Polyamides (PPA) – PPA contains a wide variety of nylons each with its unique advantages.

They are resistant to abrasion, high temperatures and chemicals except acids and bases.

• Polyphenylsulfone (PPSU) – it has resistance properties to weak acids, radiation sterilization and alkalis.

With its high toughness, it is also stable dimensionally.

• Polyoxymethylene (POM) – Its commonly called Acetal and is strong and stiff with high hardness.

With its good lubricity, it is organic solvent and hydrocarbons resistant, and also elastic and slippery.

• Polybutelene Terephalate (PBT) – it is recommended for automotive uses and power components because of its good electrical properties.

It is tough and flexible and resistant to many fuels including oils and fats.

12. How Does Single Cavity Injection Mold Compare to Multi Cavity Injection Molding?

Single Cavity is inly capable of generating just a single part in one cycle.

This means that it will have a higher unit part cost with low tooling cost because of production of low volumes.

single cavity injection mold

The use of many cavity tools at a time ensures that the Injection Mold production is continually running even with the breakdown of a single mold.

It also offers a high degree of flexibility in regulating the Inject Molding Process.

Multi-Cavity Injection Mold can generate more than a single part per cycle thus reducing the cost of a single unit part.

multi cavity injection mold

 Although with a higher initial investment, production rate is highly increased compared to the Single Cavity Injection Mold.

13. What Are The Advantages Of Injection Molding?

The advantages of Injection Molding Include:

a) It can produce a large amount of parts per hour with incredible efficiency and good per cycle time.

b) Inserts like metals or different plastics can be included in the mold by insertion.

c) Automation has enabled to greatly reduce the operation and labor costs.

d) There is an extensive variety of Polymer resins to choose from for material use.

e) Due its repeatability, product quality consistency is easily achieved.

f) Finishing requirements are reduced due little post-production work.

g) Complex part designs can be easily achieved

14. What Are The Benefits Of A Hydraulic Injection Molding Machine?

The pros of a fully Hydraulic Injection Molding Machine are:

i. Their clamping force is exceptional

ii. Their base price compared to other alternatives is relatively cheap

iii. Their constituent parts have more resistance to wear and tear with extreme durability

iv. Replacement of parts has a lower cost because they are cheap and easy to fid

Hydraulic injection molding machine

15. What Are The Practices That Reduce The Cost Of Injection Moldings?

Injection Molding can turn out to be a very costly process but several measures can be applied to lower the production cost. They Include:

• Undercuts have to be eliminated
• Part sizes have to be carefully considered during design
• Unnecessary features have to be gotten rid of
• The use of family type or multi cavity mold is highly encouraged
• The Design For Manufacturability (DFM) analysis should be closely monitored
• Existing molds can be modified and reused
• The design should focus on parts that can self-mate

16. Is Injection Molding Environmentally Friendly?

With the increase in machine efficiency, Injection Molding has become more environmentally friendly. This in addition to materials that can endure very high temperatures and conditions such as Thermosetting Polymers.

Carbon footprints has been reduced on the parts lifetime during and after manufacture.

20 to 50% less energy is required for production due to the modern technology advancements in the Injection Molding Machines.

17. What Are The Factors That Affect The Molding Shrinkage Ratio?

The Molding Shrinkage Ration is affected by a combination different mutual factors that include:

i. Injection Pressure

ii. Resin Temperature

iii. Thickness of the Molded product

iv. Injection Time

v. Injection Speed

18. What Are The Causes Of Burnt Deposits On Injection Molding?

Burnt deposits occur when pieces of molten plastic get stuck on the Injection Molding components. It is caused by:

a) A very high injection speed

b) Poor ventilation of the mold

c) High resin temperatures

d) Extended residence mold time

19. How is Nozzle Clog Up Rectified In Injection Molding?

Nozzle clog up can be rectified by increasing the nozzle diameter and raising its temperature during molding.

The cylinder temperature on the nozzle side must also be raised together with the Mold temperature.

20. Which Are The Common Injection Molding Defects?

The common defects include:

Warpage

Causes:

• Poor cooling of molten plastic
• Unsuitable gate location
• Part thickness is uneven

Remedies:

• Changing the location of the gate and adding more gates
• Low warpage materials should be used
• Even the part thickness
• Extended cooling time with lower mold temperature

Burnt Deposit

Causes:

• Poor Mold ventilation
• High injection speed
• High Resin temperatures

Remedies:

• Lower injection Speed
• Increase Vents
• Lower the cylinder temperature

Drooling

Causes:

• Large nozzle diameter
• High nozzle temperature
• Heavy back pressure

Remedies:

• Reduce nozzle diameter
• Reduce back pressure
• Change to reverse taper nozzle

 Weld Marks

Causes:

• Low injection and resin temperatures
• Poor gate location
• Low injection speed
• Poor ventilation

Remedies:

• Increase cylinder temperature
• Rearrange the gate
• Raise cylinder temperature
• Placing a vent at the vent piece

As you explain these defects, also explain how to eliminate or reduce the defects

More Resources:

Injection Moulding

Vacuum Die Casting

Gravity Die Casting

For all your injection molding needs, contact us now.