How Does Injection Molding Work?
Injection molding is a sophisticated machining process that uses specialized hydraulic or electric machinery to inject a molten plastic, or other desired material, into a metal mold that’s placed inside the machine. The material-filled mold is then held under considerable pressure and temperature, ranging from milliseconds to minutes depending on the material before it’s left to cool for a similar timespan. It is then ejected and subjected to any necessary finishing processes.
This manufacturing method requires great care and consideration in developing the mold, relying on computer-aided design (CAD) and additive manufacturing (3D printing) to create and test prototypes. But once the process is appropriately evaluated and the parameters consolidated, the many advantages of injection molding quickly become apparent.
The advantages of injection molding are many. This process can yield an all-encompassing variety of items with multitudinous capabilities. We can produce these parts in volume without sacrificing detail or complexity, delivering high quality and high yield. The exceptional potential of injection molding is invaluable: a machine can roll out thousands of items per hour. Injection molding machines can also be energy efficient while achieving consistent quality and minimizing errors.
How to Calculate Injection Molding Tonnage
Tonnage, or ton capacity, is the amount of pressure necessary to keep the mold closed. Additionally, it may refer to the maximum clamp capacity (or clamping force) of an injection molding machine.
Optimal injection molding tonnage depends on multiple factors, including the tonnage capabilities of the mold and the machine. It also hinges on the properties of the material and the projected surface area of the item molded.
How to Calculate Shot Weight
Shot weight refers to the amount of material necessary to create an item through injection molding, and therefore must be calculated before a project. Shot weight depends on multiple aspects, including maximum dosing, machine screw diameter, and material density.
Can Acrylic be Injection Molded?
Absolutely. Acrylics are synthetic plastics that contain derivatives of acrylic acid. Their plasticity and availability make them wonderfully versatile for assorted uses. They boast excellent physical qualities, lightness, and UV resistance. They’re also easy to form into various shapes, are accomplished thermal insulators, and provide exceptional optical clarity for crafting transparent parts. Acrylic plastics also offer significant flexural, tensile, and compressive strength.
Acrylics are often turned into medical components, protective goggles, refrigerator cabinets and shelves, auto parts, TV screens, sign holders, skylights, sheets used in construction, and many other elements.
Can Aluminum be Injection Molded?
Injection molding has provided impressive efficiency for many metals and alloys, though it has not shown the same results with aluminum. Until recently, thanks to a breakthrough from the Technical University Vienna (TU Wien) in 2016.
TU Wien’s advance demonstrated the efficacy of a powder injection molding process for aluminum, creating lightweight, complex forms while reducing waste and labor. This economical process can mass produce parts that would otherwise take much effort to shape. Additionally, the weight-reducing properties of aluminum make it an optimal material in the aerospace and automotive industries.
Can Polycarbonate be Injection Molded?
You bet! As a thermoplastic, polycarbonate (PC) lends itself well to being shaped according to one’s needs. The impact resistance of PC makes this material a standout when an alternative to glass is needed, as when crafting lenses for the range of eyeglasses, including sunglasses and safety glasses.
Can Thermosets be Injection Molded?
Thermoset materials feature incredible thermal capacities. Due to their ability to resist extreme temperatures, thermosets have great technological potential. They’re commonly used to create parts for car engine compartments, including pistons. Thermosets also give us switch casings and insulation rails, among other heat-assaulted items. Along with the medical and dental instruments that must survive repeated, high-temperature sterilizations.
Injection molding offers yet another wonderfully versatile fabrication method for producing parts for virtually every industry. And at Beltim, we’re thrilled to help you explore the benefits of top-quality, reliable, efficient machining. So get a free quote or contact us today to inject some excellence into your next project!