Plastic injection molding is a complex process, but it’s simple in principle: melted plastic is forced into a closed mold that defines the shape of a finished product. The process is a great choice for manufacturing complex, high-quality components that need to be strong, rigid, and durable.
Plastic injection is a common manufacturing method used to produce a wide variety of products, including automotive parts, consumer goods, and medical devices. It is an efficient, cost-effective technique for producing high volumes of identical parts because it can be performed at a much higher rate than manual methods like stamping or forming.
A key step in plastic injection is selecting the right thermoplastic for your product’s specific needs. Different types of polymers have varying chemical, physical and structural properties. Choosing the wrong material can have significant consequences for your final product.
To select the appropriate material, consider your product’s design, the environment it will be subject to, and the characteristics that you need it to possess. For example, products with bendable sections or living hinges should be made from flexible materials such as polypropylene, while structural parts require stiff plastics that are resistant to chemicals and abrasions, such as PEEK.
Once you have selected a thermoplastic, you will need to choose the best mold for your project. The type of mold you will need depends on the volume and complexity of your product. For smaller production runs, a single-cavity mold is often enough. A multi-cavity mold is more suitable for large-volume production because it can manufacture multiple components at the same time.
The plastic injection machine starts with a hopper that holds the raw, pelletized plastic. The hopper is attached to a hydraulic rotating screw that’s driven by an electric motor. As the screw rotates, it melts the plastic and transfers it from the hopper to the nozzle that injects it into the mold cavities. The injection machine controls the speed of the screw and pressure as the plastic fills the mold cavities, allowing for precise control of the entire process.
Injection molding machines also have a system of vents to allow air to escape during the injection process, preventing overheating. Once the molten plastic has filled the mold cavities, it is cooled to its solid state. The injection machine then replaces the screw’s pressure with holding pressure to compact the molded plastic and compensate for shrinkage that occurs during cooling. After the molded plastic has cooled for a period of time, it is removed from the mold and trimmed to remove any excess plastic.
In addition to trimming, the last step of plastic injection is applying a chemical release agent to the molded part to help it separate from the mold. This can be reapplied periodically as needed, or it can be fixed permanently on the surface of the molded part.