Polypropylene Injection Molding
InoxCast manufacture and design custom polypropylene injection molding for industries and businesses across the world. And we work with many thermoplastic materials to provide the best result in producing highly durable polypropylene injection mold.
- Advanced and latest production line
- Custom polypropylene injection molding is available
- 100% testing & inspection before shipment
- 20+ years of experience
Why Inox Polypropylene Injection Molding is Your No.1 Selection
We design and manufacture polypropylene injection molding through our advanced molding equipment. Supported by our professional staff and engineers, Inox polypropylene injection molding is 100% inspection guaranteed before delivery. We are a professional OEM, ODM manufacturer that can really support your business.
InoxCast can custom your ideal plastic parts injection molding according to your specifications. Please send us your requirements now!
We can manufacture a wide array of high-precision polypropylene injection molding that are available in many designs.
Inox provides CAD and UG services to manufacture high-quality ABS Polypropylene Plastic Mold Injection Molding. You can send us your inquiry now!
Inox, as a leading manufacturer in China, can manufacture polypropylene injection molding for plastic cases.
InoxCast is an expert manufacturer of polypropylene injection molding for electronic parts for over 10 years.
We offer low cost polypropylene injection molding that are able to produce different plastic parts.
We offer a wide range of clear polypropylene injection molding that are suitable for electronic parts.
Inox OEM Design Polypropylene Injection Molding both have vertical and horizontal type injection machines.
We offer top-quality polypropylene injection molding with high flexibility in dimensions and shapes.
Inox is a professional manufacturer of polypropylene injection molding that are suitable for molding fishing lure.
We can custom Polypropylene Expanded Injection Molding according to customer’s drawing or samples.
Inox Your Professional Polypropylene Injection Molding Manufacturer
InoxCast Polypropylene Injection Molding
One of the best materials for injection molding is high-quality polypropylene plastic. Inox Polypropylene injection molding also named PP injection molding is used in a wide range of applications. If you’re looking for a reliable PP injection molding manufacturer and supplier, Inoxcast is the best solution!
Inoxcast PP injection molding is designed to produce more complex forms of polypropylene which cannot be made if it was in its original form.
Inoxcast manufactures all kinds of PP injection molding such as storage containers, plastic boxes, and bottles. Our PP injection molding is useful for different types of water bottles, kitchenware, plastic storage containers, and even piping systems and insulation.
You can put trust in Inox Cast’s vast experience in the industry and capability in supplying durable and cost-effective polypropylene injection molding solutions. As a leading manufacturer in China, we provide a wide option of polypropylene injection molding products available in different shapes, styles, designs, capacities, and sizes to suit your required applications.
The following are the PP injection molding advantages:
- easy to access and not expensive
- not expensive
- possesses a high flexural strength by virtue of its semi-crystalline property
- rather resistant to moisture absorption
- characterized by a relatively slippery surface
- chemically resistant to an extensive range of acids and bases
- fatigue resistance
- great resistance to impact
- act as a great electrical insulator
Inox is your reliable PP injection molding provider in China, offering almost all types of plastic components and parts. Our company has hardworking employees and skillful engineering personnel.
We aim to customer’s happiness when it comes to polypropylene injection molding needs. Inoxcast can provide a one-stop-shop PP injection molding solution to all our valued clients.
Skyrocket your business with Inoxcast and earn customer satisfaction. For more information, please don’t hesitate to contact us for queries.
Polypropylene Injection Molding: The Ultimate Guide
This guide covers all information you need about polypropylene injection molding process.
From injection molding requirements, molding techniques, applications to molding process – you will find all information right here.
Take a look:
- What Is Polypropylene Injection Molding?
- Polypropylene Injection Molding Parameters And Conditions
- Advantages Of PP Injection Molding
- Limitations Of Injection Molding Polypropylene
- Properties Of Polypropylene Making Suitable For Plastic Injection Molding
- Polypropylene Injection Molding Process
- How To Reduce Polypropylene Injection Molding Cost
- Recommended Polypropylene Injection Molding Temperature
- Choosing Mold For Injection Molding PP
- Allowable Polypropylene Injection Molding Tolerances
- Polypropylene Injection Molding Defects
- Types Of Polypropylene Injection Molding Techniques
- Injection Molding Polypropylene Resin Tips
1. What Is Polypropylene Injection Molding?
A thermoplastic addition polymer that combines many propylene monomers is known as Polypropylene injection moulding material.
Polypropylene injection moulding is the process of transforming solid polymer to molten phase then directing it into a premade cavity to form a product.
polypropylene injection molding
In processing isotactic polypropylene (iPP), polypropylene injection moulding is the method widely used.
A mould formed by reciprocating the screw injects due to a screw in a heated barrel rotating to transport, melt and pressurize the polymer in the barrel.
2. Polypropylene Injection Molding Parameters And Conditions
The following are the polypropylene injection moulding conditions:
- Plastic injection moulding pressure
- Mold temperature
- Melting point
3. Advantages Of PP Injection Molding
The following are some of the advantages of PP injection molding:
- PP has a corresponding slippery surface.
- Minimal costs are incurred, and access is more accessible.
- PP is an excellent electric insulator.
- Its semi-crystalline property makes it have a high spiral strength.
- PP is resistant to exhaustion.
- PP is excellently resistant to impact.
- PP is chemically resistant to a vast range of acids and bases.
4. Limitations Of Injection Molding Polypropylene
The following are the disadvantages of injection molding polypropylene:
- Highly flammable
- Its poor bonding properties make it challenging to paint on it.
- PP is very sensitive to Ultraviolet(UV)
- Its high temperature is limited because it has a high thermal expansion coefficient.
- PP is highly resistant to chlorinated aromatics and solvents
5. Properties Of Polypropylene Making Suitable For Plastic Injection Molding
Polypropylene material has the following properties that make it suitable for plastic injection molding:
Resistance To Exhaustion
After undergoing bending, flexing, or torsion, polypropylene maintains its shape and is thus considered suitable for making living hinges.
Toughness And Elasticity
Polypropylene acts differently in materials during the deformation process.
To a fixed range of deflection, polypropylene acts with elasticity also during the early stage of the deformation process, and it can also experience plastic deformation hence toughness.
Polypropylene is suitable for electronic component uses because it is highly resistant to electricity.
Polypropylene is naturally manufactured with a natural opaque colour even though it can be made transparent.
Polypropylene is suitable for applications that require the transfer of light.
Resistant To Chemical
Polypropylene is suitable for containers such as first-aid products and cleaning agents because it does not voluntarily react with dilute acids and bases.
6. Polypropylene Injection Molding Process
The following are the steps to be followed for the polypropylene injection molding process:
The design of the screw has a significant impact on the injection molding process of PP because the process depends on it to drive the fluidity.
Output is affected by the diameter of the screw.
The compression ratio effects of the screw influence the pressure value and the volume and finished product effect.
To accelerate the fluidity, friction heat energy will be produced by the friction of raw materials even though the flow of raw materials majorly depends on the heater.
Therefore, the flow is small, the screw compression ratio is small, and the rotational speed should be maximized, leading to more friction heat than the screw with a large compression ratio.
The heater makes raw material particles melt into liquid flow gradually.
If the temperatures increase, it will fasten the flow of raw materials, leading to an efficiency increase, but that does not warranty positive results.
Therefore temperature balance needs to be arrived at.
Mold or Mold Head
Mold or mold head is a significant factor in plastic retyping.
The shrinkage rate should be considered, the mold is more complex, and the injection molding product is three-dimensional.
Other products are strip, flat and needle-like continuous product heads.
The production efficiency can be improved by the considerable pressure caused by the extrusion force directed by the screw at the small outlet.
The injection mold has a cooling chamber where the material design is cooled.
Except for the air knife, which cools water directly on the blowing bag, hollow air blowing, and other cooling methods, for extrusion molding to attain a cooling effect.
It depends majorly on the cooling channel in the roller.
Extruded products have various elongations. To enhance the extension of finished products is through processing.
In high-speed production, the molecular weight distribution can affect the elongation effect.
Another form of extrusion is vacuum and air compression molding.
The internal stress caused by cold contraction, crystallization, and expansion leads to shrinkage problems of raw materials.
Maintaining pressure continuously and prolonging cooling time helps curb cold contraction and thermal expansion.
Compared to non-crystalline materials, crystalline raw materials are likely to have a considerable shrinkage difference.
This part is fixed in the mold by adding additives to reduce shrinkage.
Polypropylene injection molding process
7. How To Reduce Polypropylene Injection Molding Cost
There are different ways to reduce the mold cost because the injection molding process is quite expensive.
The following are ways in which mold costs are reduced:
- Considering the part size
- Exclusion of undercuts
- Eliminating irrelevant features
- Initiating the use of family type or multi-cavity mold
- Using a core cavity technique
- Minimizing cosmetic finishes
- Redesigning and re-using the existing molds
- For parts that self-mate, it is crucial to design them
- Monitoring the DFM (Design for Manufacturability) analysis
8. Recommended Polypropylene Injection Molding Temperature
Polypropylene is recommended to be molded at a cylinder temperature ranging between 400 and 5000 F to yield positive results.
The cylinder temperature should range between 52 and 500 F higher than the minimum temperature needed to fill the part.
Molding temperatures mostly range between 400 and 5250 F.
If temperatures lower than 4000 F is used, it can lead to poor quality surfaces and flow marks.
If temperatures higher than 5000 F are used, it can result in shrinkage, warpage, burning, and flashing.
9. Choosing Mold For Injection Molding PP
When choosing the mold for injection molding of polypropylene, the following are the properties to consider;
Cost Of Material
The material cost is an essential element to consider when choosing fabric for the injection molding process as it will help get a clear budget of the costs to be incurred.
Weight Of Material
The weight of the end product will be determined by the density of the polypropylene used in the injection molding process.
The density will help determine how light or heavy the result will be after being manufactured.
Flexibility Of Material
The material’s elasticity is a significant factor when choosing an injection molding material.
Resistance to indentation or material hardness is measured using a device to measure the shore hardness.
Then are separated into two types measuring the more complicated and softer polypropylene materials.
The scale for both types ranges from 0 to 100
It is essential to choose the right polypropylene for the correct part production as each different material is used for various applications.
The following are the factors to be considered when choosing the material:
- Environmental conditions
- The material uses
- Abrasion type
- Experiences incurred by the user on using the material.
Therefore, choosing the material that can withstand temperatures, erosion, and pressure is crucial.
Surface Of Mold
The mold surface should have a thick, wear-resistant, and hard layer.
Size And Precision Requirement Of The Injection Molding Process
There can be high-precision and low-volume injection molding; therefore, choosing the material based on production size is essential.
10. Allowable Polypropylene Injection Molding Tolerances
Allowable polypropylene injection molding tolerances are +/-0.005 inches.
Parts with tight tolerances are more expensive to produce than parts with normal tolerances.
Hence, it is essential to find the optimum tolerance for parts that manufacture high-quality results at a minimal cost.
The following are some of how engineers and designers need to optimize part tolerances:
- Administering repeatable process controls
- Know injection molding tooling
- Knowing properties of materials you want to injection mold
11. Polypropylene Injection Molding Defects
The following are the polypropylene injection molding defects.
- Shrinkage deformation
- Vacuum hole
- Bending deformation
- Weld line
- Cracking and whitening
- Surface porosity
- Under injection
- Overflow flash
- Flow mark
- Silver streaking
12. Types Of Polypropylene Injection Molding Techniques
Some of the polypropylene injection molding techniques include:
The reaction injection molding process is used to mold polypropylene.
It is a low-temperature and low-pressure injection process.
The process is majorly used in industrial, automotive, and medical industries.
Parts that are lightweight and strong and can be painted easily are often molded using reaction injection molding.
Reaction injection molding involves a two-component system made of isocyanate liquids and polyol mixed at high pressure, and then at low pressure, they are metered into the closed tool.
After expanding, the material is ejected in 5 minutes to fill the tool.
The first step in the reaction injection molding process involves dispensing the isocyanate and polyol (polypropylene) liquids in storage tanks under high-pressure pumps.
reaction injection molding
The polypropylene is redistributed from the storage tank to a multi-stream mix-head and back in a vicious circle.
This injection molding process uses low-viscosity liquid polypropylene. They then thicken and stretch through various chemical reactions.
The polypropylene finally hardens after being injected into the heat mold.
Some of the advantages of reaction injection molding include:
- Minimal tooling cost
The reaction injection molding process enables tools to be produced faster and lower costs.
- Large parts
Polypropylene properties allow it to fill molds for substantial parts.
Reaction injection molding is flexible as both thin and thick walls can be designed.
- Lightweight, solid and flexible parts are produced and can be painted
- Fast cycle times
Limitations of reaction injection molding include:
- Raw materials are costly
- Compared to injection molding, it has slow cycle times
Gas-assisted injection molding process involves a polypropylene melt pushed into the mold at the end of the polymer stage by an inert gas at pressure.
- Low clamp force
- Thick parts can be molded
- There are no sink marks
- Products are lightweight
- Part deformation is reduced
- Plastic materials are an exception to this method
- The method is challenging for the production of multi-cavity mold.
Gas assisted 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
thin wall injection molding
Injection Molding Of Liquid Silicone Rubber
Injection molding of liquid silicone rubber is an injection molding process that involves polypropylene 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.
liquid silicone rubber injection molding
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
2k Injection Molding
2K injection molding involves molding using two different colors or polypropylene materials. The process is economical and efficient.
Two materials with different colors, properties, and hardness levels are manufactured into one end product using the 2K injection molding process, thus saving costs.
2K injection molding
Some of the benefits of 2K injection molding include;
- The appearance of the end product is more attractive
The end product is more appealing because it can be made from two colours in one production process, and the two components can fit together perfectly.
- Saves on production costs
The cost price of products is low because 2K injection molding gathers steps together into one injection molding process.
- Is compliant with the user and tailor-made products
Some of the disadvantages of the 2K injection molding process include:
- Combining some plastics might not be possible as some do not bond adequately.
- It can be expensive as the one-time investment cost for a 2K injection molding process can be higher than a single injection molding process.
13. Injection Molding Polypropylene Resin Tips
Polypropylene has a low density and is resistant to chemicals; hence considered a suitable material for producing items such as automotive parts and medical devices.
Therefore, polypropylene has acquired popularity in the injection molding field.
Temperature thresholds need to be monitored during the melting and molding process. Thus, polypropylene resins are used because of their benefits.
The following are the tips for injection molding polypropylene resins:
Using A Melt Temperature Ranging Between 4000 F And 5000 F
When setting a temperature melt, ranging between 25 and 500 higher than the minimum fill temperature should be considered.
If temperatures lower than 4000 F is used, it can lead to poor quality surfaces and flow marks.
If temperatures higher than 5000 F are used, it can result in shrinkage, warpage, burning, and flashing.
Ensuring That Proper Molding Equipment Is Available
Even though polypropylene can be molded accurately using standard and unaltered single-stage screw molding equipment,
It is always essential to ensure proper molding before starting the injection molding process.
Don’t Rush The Injection Process
In order to consume a high volume of each overall cycle, it is good to be prepared before the injection process.
The injection process needs patience because accurate injection helps control shrinkage as injection time does not remarkably influence warpage.
If Using Fixed Polypropylene Resins, Consider Pre-dying Only
Polypropylene is a non-polar substance, and the pre-dying process can be skipped, thus saving time during the injection molding process.
Few filled polypropylene resins are the only resins that may require pre-dying.
Go For An Injection Pressure Ranging Between 800 And 1,500 PSI
Injection molding problems with polypropylene resins can be controlled by injection pressure as an element.
The injection pressure chosen should match the size and construction of the item.
To avoid problems with sticking and flashing, the injection pressure selected should be capable of roughly filling 99% of the item’s part.
Hold Time Should Not Be Rushed.
Hold time is an essential factor in preventing shrinkage and warpage. Giving enough time for the mold to cool is necessary.
It is recommended to allow the part to cool to approximately 1300 F to yield positive results.
Choosing A Mold Temperature Ranging Between 500 And 1500F
To reduce surface imperfections and stress, mold temperatures should be accurately determined.
Mold temperatures ranging between 500 and 1500F help minimize stress and surface imperfections.
To facilitate the component’s ejection from the mold, it is essential to ensure that the mold is cooled uniformly.
Always Ask For Help From Qualified Industry Professional
This is the best technique to ensure positive results are yielded.
Always ask for instructions and guidance from well-trained industry professionals during the PP resin injection molding process.
To Improve The Cycle Time, Use Minimal Back Pressure
The best backpressure for polypropylene injection molding is recommended to improve cycle time to range between 50 and 100 psi.
Though there are cases that require pigment mixing, this rule is an exception.
If Sticking Occurs, Adjust The Polypropylene Grade
Polypropylene has release properties that prevent it from sticking.
If sticking occurs, it is easily corrected by using a polypropylene grade internally lubricated or slight changes to the mold.
For all your polypropylene injection molding needs, contact us.