Small Scale Injection Molding

Inox Cast – Your Trusted Small Scale Injection Moulding Manufacturer

Inox Cast small scale injection molding is designed for better performance and quality productions. It has the capacity to produce products with premium quality and will surely hit your market.

Inox Cast offers top-rated small scale injection molding available in standard and customized designs. We have a wide range of this molding comprising different models, sizes, and production capabilities.

With our small scale injection molding, the increase of profitability and capacity of your facility is guaranteed. We made this equipment to fit your productivity and space specifications.

Rest assured, the usage, maintenance, and installation of our small scale injection molding only require minimal effort. It is designed with safety measures that avoid work-related injuries and accidents.

Inox Cast only uses the CE and ISO9001 certified products. Our small scale injection molding is made from high-quality materials, ABS, metal, PET, PVC, etc. You can have this equipment in OEM and ODM services.

Our small scale injection molding only uses a moderate amount of electric energy giving you more efficient and cost-effective performance. With our machine, you will experience the best value for your money.

Inox Cast produces small-scale injection molding with high durability and outstanding performance. This will help you earn more production time and enough labor-saving.

We want to give you satisfactory machines, equipment, and world-class products. Our company makes sure that each small scale injection molding we produce came through our advanced CNC machines and automated CMM machines.

For 20 years, Inox Cast has gained enough capability to produce small scale injection molding and other equipment with excellent services. The company’s main goal is to exceed the customers’ expectations in all aspects.

Inox Cast is eager to be your trusted small scale injection molding provider in the future! You can send us your inquiries anytime.

Small Scale Injection Molding: The Ultimate FAQ Guide

If you are looking for any information on small scale injection molding – everything you need is right here.

So, keep reading to learn more.

1.  What Is Small Scale Injection Molding?

small scale injection molding

A process in which plastic materials in a minor extent pass through heat and pressure, hence turning into molten forms.

The plastic then cools and turns to molds after the curing process.

The process goes through four major stages before solidification.

They then pass through the cooling process to solidify the parts to desirable shapes.

2.   What Are The Benefits Of Small Scale Injection Molding?

Cost Saving Process.

The manufacturer takes a short time period to deliver the products to reach the market.

This is because the production process cycle is short hence speedy outputs.

Enjoys The Advantage Of Flexibility In Design

It is easier to change on the design of the injection molding products if they are in small quantities.

Easy To Manage Inventory At A Close Range.

There is easy supervision and management for the small quantities.

This also enables bridging for various scale productions because the quantity allows for flexibility in design change.

There Is Maximum Product Specialization.

Manufacturers are at a position to apply efficient technical know-how in the injection molding process.

Initial Small Capital Investment.

The amount of capital set for production is not extensive, hence easy to track sales and profits.

Efficient Flow Of Communication.

Allows for direct communication and relationship between the buyers and the manufacturers.

The advantage gives the producer an easy chance to meet the customer’s specifications.

This is because through close interactions, they get clear feedbacks from customers.

3.  What Are The Limitations Of Small Scale Injection Molding?

 High Cost Of Tools And Installation.

The initial cost covers designing, testing and installing the tools.

There is initial design and prototyping, then follows designing of the prototype   mold tool to produce its replicas in large volume.

This becomes cost effective if the production is in large scale, because the sales    volume can cover for the extra costs.

 Restrictions In Part Designs

The basic rules of injection molding must be in use during plastic part design.

For instance, avoiding sharp edges and undercuts.

The thickness of the wall should be uniform to avoid inconsistencies during cooling    and      use of draft angles for better molding.

Changing designs of metal tools is very difficult hence require starting over gain.

Small Runs Parts Are Expensive To Injection, Mould On Small Scale.

This is dues to the tooling complexity and the requirement to rid the machine of all preceding material before the net production.

The set up time is therefore quite costly.

4.  Which Features Should You Consider When Buying Small Scale Injection Molding Machine?

Shot Size

The maximum amount of material, the plastic that the moulding machine can inject in the moulding cavity within one moulding cycle.

The machine should be able to produce 30-40% more shot sizes than that the requirements of the parts.

Tonnage.

This refers to the clamping pressure.

It is determined by the number of tonnes the machine can direct downwards on a work piece to produce adequate parts.

Platen Size

This is the part that holds the moulding cavity.

It determines the size of moulds to place into the machine.

Tie Bar Spacing

This determines the maximum size of moulds to place in the moulding machine for production.

5.  How Do You Choose Mould For Small Scale Injection Molding?

       Consider The Speed Of Building.

Carry out evaluation of the requirements of your project.

This enables you to identify which exact mold you need to work with.

Whether to build a prototype or production-ready mold.

       The Stage Of The Project You Are Developing.

Here you check the exact position where you are in the project development.

Consider if it is the, prototype, design, pre-production or production stage.

This gives light on which specific mold to select, so as to save on extra costs and time for                            changing molds.

      The Amount of Output Parts from the Production.

Having an idea of the quantity output one wants to produce from a specific mold.

Regardless of the quantity, factoring in future changes in the process, go for a strong mold.

    Complexity/Simplicity of The Project.

Consider a strong mold that contains inserts with hard steel material.

This gives room for flexibility of design changes until one decides on the main final   design.

    Cost Of The Initial Mold Build.

The cost of the mold relies on various factors.

Consider factors such as the complexity of the parts, classification and mold cavitations.

The specialities allows one to understand the cost that goes into building the mold.

6.  What Are the Key Stages In Small Scale Injection Molding Process?

Clamping Stage.

Assemble the two halves of molds and put securely in the clamping unit.

They then attach to the injection molding machines, as one half slides on the base plastic.

Then the mold securely close through exertion of the clamping force.

Injection Process.

Firstly, there is the assembling of the plastic materials in pellet form and then put in the injection molding machine.

The process involves melting of the materials by heat and pressure.

The plastic in molten form quickly injects into the mold and pressure packs build up holding the materials.

small scale injection molding machine

Cooling Of The Molten Plastic.

This process allows the plastic in molten form to begin cooling in the mold.

This happens immediately it gets in contact with surfaces in the interior part of the mold.

Cooling enables the plastic to solidify to the preferable shape.

Ejection Process.

Ejection is the last stage where the part in its solid form comes out through exerting a pull out force.

7.  How Can You Reduce The Cost Of Small Scale Injection Molding?

Shorter Setup Times.

This process requires an extra machine whereby its being set up when the other machine is working.

By so considering this, it allows for other jobs to run smoothly, hence faster production.

 Scrap Reduction.

Scrap highly impacts to the  expenditure of a company .

Proper monitoring allows a company to do away with loss of materials in form of scraps.

Thus reducing the cost of the material loss.

  Optimum Run Size First.

Here the plastic injection machines have to constantly run with very minimal interruption.

This is less costly as it saves on time and shortens the lead times for the parts.

8.  How Can You Increase Efficiency Of Small Scale Injection Molding?

Through Cycle Time Reduction.

The adjustments on cycle time majorly improves on the speed of the mould.

Hence increasing the efficiency of productivity in injection molding.

Scrap Reduction

It also needs to be closely monitored because scrap is a function of production rate and labor expenditure.

Better Cooling.
The time period that parts take to cool is the greatest factor in the cycle of plastic molding.

Invest in a good cooling system which is consistent and very reliable in the processing of plastic.

Efficient control on the cooling time increases the efficiency of small scale injection molding.

Only Add Processes When Needed.

Only work on the addition of part finishes that are relevant to your product specific purpose

Maximize On Pieces Resulting From Your Tool.

Primarily works on lowering the costs per-part, resulting to cost saving on the mold and improving production efficiency.

Speedy production also results in instances where one can feed a mold with more shots at once and maximize production.

  Simplify As Much As Possible.

Work on reducing the complexity of the product design if it is not purpose specific.

Do away with elements not so important to your project, so as to save on both time and expenditure costs.

9.  What Are Common Defects In Small Scale Injection Molding?

 Flow Lines

They are the lines that appear in different off-toned colors on the prototype parts.

This is because of the variation of speed in which the plastic in molten form flows through the changing contours in the mold.

They also form as a result of slow injection speed causing different solidification rates.

Preventions:

1. Enhance uniform solidification of plastic by increasing the speeds of injection and pressure.

This ensures proper filling of the cavities in the mold tool.

2. Create a gate at a specific spot that has thin walls in the tool cavity.

Sink Marks

The depressions that results on thicker zones of the prototype when there is shrinkage on inner parts of the end product.

Mostly occurs due to insufficiency on the cooling mechanism, hence fail to support complete curing of the plastic.

Also results due to inadequacy of pressure in the cavities

Preventions:

1. Ensure there is increase in the holding pressure in the cavities.
2. Consider low temperatures in the mold.
3. Allow adequate time period for proper curing and cooling.

Vacuum Voids

They are pocket like bags of air traps lying within the surface of a prototype in the injection mold.

Mostly resulst from insufficiency of the holding pressure or imbalance in the solidifications of the prototype inner sections.

Preventions:

1. Find a zone with the thickest part of the molding and locate the gate.
2. Consider on a plastic that is less viscous.
3. Ensure high levels of the holding pressure.
4. There should be proper alignment of the molding parts.

Weld Line.

They are plane like lines that form at a point where the molten plastics meet when flowing from different sections of the mold.

Results from inadequacy in the bonding of the flow fronts due to the molten plastic solidifying partially.

Preventions:

1. Increases the temperature of the mold.
2. Ensure high speed of injection.
3. Consider a plastic with less viscosity rate.

Burn Marks

They are the discolorations on the surface of the prototypes. They mostly appear as rust.

Mostly appears when the plastic degrades due to excessive heat

Preventions:

1. Reduce injection speeds.
2. Optimize gas venting and degassing.
3. Reduce mold and melt temperatures.

10. Which Are The Common Types Of Small Scale Injection Molding Processes?

Thermoplastic Injection Moulding

This process injects thermoplastic resin in the mould where it cools forming the final part.

thermoplastic injection molding

Insert Moulding-

In this process, you first insert a component in the mould before resin enters.

Then inject the material  and direct it to  flow around the insert forming the final part.

insert molding

Over Moulding

Preferable when manufacturing plastic parts with more than one materials.

over molding

Liquid Silicon Rubber Moulding

It uses the -thermo set materials and a chemical reaction solidifies the plastic part.

liquid sillicone rubber molding

11. Is Low Volume Injection Molding Same As Small Scale Injection Molding?

Yes.

In both it refers to the production of parts in quantities of 100,000 or below.

ow  volume injection molding

12. Which Materials Can You Use In Small Scale Injection Molding?

Metal Injection Molding Acrylic (PMMA)

Poly(methyl methacrylate) is a strong thermoplastic that is clear in nature, and   provides a shatter-resistant  glass.

PMMA is transparent thus offering excellent clarity for optical options.

Advantages.

Resistant to sunlight.

Does not absorb odors.

Contains powerful tensile strength when under force.

Limitations.

They are very costly.

Easily absorbs greases hence staining.

Poor resistance to solvents.

Nylon Polyamide (PA)

Consists of categories of materials that are natural and others synthetic.

Nylon, being an example of a synthetic material.

Advantages.

Nylon is highly resistant to heat.

Has a great resistance to abrasion.

Contains low co efficiency of friction.

Nylon material is very tough in nature.

Limitations.

Nylon easily burns.

The material is prone to sunlight degradation.

Nylon lacks resistance to strong base and acids.

Polycarbonate (PC)

The materials are naturally tough and transparent.

Advantages.

Polycarbonate is a durable material.

The material is light in weight with great optical characteristics.

Limitations.

Polycarbonate is costly to mold as there must be very high temperatures for processing.

The material is easily prone to scratches.

Thermoplastic Elastomer (TPE)

Thermoplastic elastomer (TPE), or the thermoplastic rubber (TPR), results from blending plastic and rubber components.

The method of processing is the same for both (TPE) and (TPR) materials.

Advantages.

Thermoplastic elastomers possess a great stretching power.

Involves lower costs of molding.

They retain their original shape even after stretching.

Limitations.

The material has poor heat resistance.

tabletop injection molding machine

13. Is There Recommended Wall Thickness Of Small Scale Injection Molded Parts?

The thickness should range from 2mm to 4mm.

Additional Resources:

Mini Injection Molding

Thermoplastic Injection Molding

2K Injection Molding

Mold Components

For all your small scale injection molding needs, contact us now.