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When does Injection Moulding get used?

Injection Moulding

There is a multitude of products that can be produced using injection moulding, including common plastic items such as bottle tops, remote control casings, syringes, and more. Larger items, including car body panels, are usually made with this technology. In China, there are many injection molding companies. Here is the best Injection molding China you can choose.

An injection mould is typically used when many thousands or millions of identical components must be manufactured from the same mold.

Types

The injection molding process can take many different forms, including:

  • Cube moulding
  • Die casting
  • Gas-assisted injection moulding
  • Liquid silicone rubber injection moulding
  • Metal injection moulding
  • Micro injection moulding
  • Reaction injection moulding
  • Thin-wall injection moulding

Materials Applied

Plastic Moulding 600x450 1

Different materials can be injected into an injection mould, including metals, glass, elastomers, confections, and, most commonly, thermoplastics and thermosetting polymers.

There can be a variety of properties and effects achieved by combining different materials.

Benefits

Injection moulding’s main advantage is that it can produce large numbers of parts in a relatively short period of time. However, once the design and mould costs have been covered, the cost of manufacturing is low. As more parts are produced, the cost of production drops.

Additionally, injection moulding generates less wastage than other manufacturing methods, such as CNC machining, where excess materials are cut off. The injection moulding process still produces a certain amount of waste, mainly around the sprue, the runners, the gate locations, and the overflow material that leaks from the part cavity (also known as flash).

Lastly, injection moulding offers the advantage of producing many identical parts, allowing for high volume production of parts with a high degree of reliability and consistency.

Problems

There are a number of advantages associated with injection moulding, as well as some disadvantages.

When it comes to injection moulding, upfront costs can be high, especially when it comes to tooling. A prototype must be created before any parts can be produced. It is then necessary to create and test a prototype mould tool. Each of these steps can be time-consuming and costly.

Similarly, injection molding is not ideal for producing large parts in one piece. Injection mould machines and mould tools are limited in size because of this. Injection moulding machines cannot create parts too large for their capability, so they need to be produced in multiple parts and subsequently welded together.

Final disadvantage: undercuts of this scale require expert design to prevent and can increase the cost of your project.

Applications

When a repeatable manufacturing process is needed, injection moulding is the ideal choice. The products manufactured here include wire spools, packaging, bottle tops, toys, combs, musical instruments (and components), chairs, small tables, storage containers, mechanical parts, and automotive parts.

Particularly in high-volume injection moulding company, injection moulding is the most common method.

Conclusion

For manufacturing, injection moulding can be used to produce a wide range of parts, especially those that are produced in large volumes. Although the cost of the tooling and molding can be high, once this is complete, the cost of manufacturing is low. For parts made of a variety of materials, injection moulding provides the capability to produce parts that are nearly identical.