Description of plastic injection molding technology
Injection molding is highly efficient and productive way obtaining plastic products of complex design and different thicknesses in large volumes. Plastic injection molding takes place in mold Is a device for the manufacture of plastic products that produces millions of identical products per year … Thus, injection molding is ideal for high-volume production of plastic enclosures, parts, equipment parts, etc.
For the production of plastic products, contact KLONA. We provide the best conditions for cooperation on the Ukrainian market and guide the client from the first consultation to the sale of products.
Injection molding cost
The cost of injection molding depends on the complexity of the preparatory stages and design features of the future mold … The price of plastic injection starts from UAH 110,000 … It includes all the design and manufacture of the mold, as well as the cost of the first test casting.
Equipment for the manufacture of plastic products
To get plastic injection, three things are needed – a plastic injection mold, an injection molding machine and a plastic bag. Plastic in the form of granules or powder is poured into the dispenser, melted and fed into the mold. At the same time, the punch (the movable part of the mold) closes with the die and the product is formed. After that, it is cooled and pushed out of the mold by a system of pushers. In our production are installed injection molding machines of the ARBURG 320C, ARBURG 420C, HAITIAN HTF160X models.
PRESSURE CASTING STAGES TO ORDER
Mold design and 3D modeling
In order to start the production of plastic products, you need to make a mold. It all starts with building 3D models future product, on the basis of which the model of the mold itself is built. She must exactly repeat the shape of the product , as well as rationally use the material. When designing a mold for plastic injection, engineers need to choose the optimal section for the product, think over the layout of the cavities, the device of the gating system and auxiliary systems. Necessary take into account mold wear and the specifics of the downloads. An improperly designed mold will result in waste of materials and will quickly fail. +
KLONA employs top industrial designers and engineers to maximize mold productivity. Custom injection molding – the first step towards realizing the dream of your own business.
Injection Mold Manufacturing
After modeling, the 3D model of the mold is broken down into separate components. The production of molds takes place made of high quality steel on special machines with CNC in the tool shop. The precision of modern mold making equipment allows the mold to be perfectly recreated from the model. After that, all the parts of the mold are assembled and lapped, a cooling system, pushers and molten material supply is installed.
After assembly, the mold casts its first product. The accuracy of the casting, the quality of the product obtained, the consumption of material, etc. are checked. Typically, a test casting includes up to 200 iterations, which should reveal the slightest defects.
Modification of the injection mold
In case of revealing defects in the work of the mold or in the cast products, the mold is sent for revision.
Manufacturing of plastic products
When all the nuances have been taken into account and the shortcomings of the mold have been corrected, it’s time to start your production! To do this, the mold is installed on an injection molding machine, connected to the systems of its “life support” and begins to produce a specified number of products per year.
ADVANTAGES OF DIE CASTING
Low cost per item
Due to its high cost, injection molding is used for large-scale production of parts or products (from 1000 pcs). Each subsequent casting reduces the cost of products , and the price of one part from a large batch with millions of plastic products will be only a couple of cents.
The ability to manufacture complex products
Production of products by injection molding allows the production of small parts of different thickness and complex configuration. The use of multi-cavity molds can increase productivity several tens of times at once (for example, in the production of handles). In addition, special parts of the mold – inserts – make it possible to immediately produce parts with holes, notches or bulges.
Low probability of marriage
The whole injection molding process fully automated, which eliminates the possibility of errors on the part of the operator. As a result, we get the required number of products in exactly the same excellent quality.
No post processing needed
The injection molding process involves the production of a finished plastic product that will not need additional processing. Even decoration can be done with built-in threads.
The number of press cycles is not limited. Once you order a mold, you can use endlessly , replacing parts as they wear out. Additional chrome plating of the mold will protect it from aggressive materials.
The quality of the products is on highest level: no flaws on the surface of products, no roughness, brittleness or porosity.
Wide range of materials
When ordering plastic injection molding from KLONA, you can choose the most suitable type of plastic and its color from a wide palette. You can also order transparent plastic molding.
APPLICATIONS IN PRESSURE CASTING
Areas of use
Injection molding is applied for large-scale production and it is impractical to use it for the manufacture of only a few products.
In general, casting is used in all areas where it is necessary to produce a large number of identical plastic products. For example, for the manufacture of plastic containers, plates, bottles, children’s toys, medical equipment, office supplies. Also, plastic injection into molds is used in the engineering and rocketry fields, for construction purposes, etc.
MATERIALS FOR MANUFACTURING PLASTIC PRODUCTS TO ORDER
Types of plastics
For the manufacture of plastic products, thermoplastics and thermosets are used. The former are recyclable, since they lend themselves only to physical transformations during the formation of the product. Reactoplastics undergo irreversible changes and turn into solid infusible materials. There are two types of injection molding, depending on the type of plastic.
Injection molding of thermosetting plastics
Most often it is used to obtain massive and thick-walled parts. In this type of casting, the prepared material is injected into an incompletely closed mold. It closes completely at the end of the injection. Products made of thermosets have an improved surface.
Injection molding of thermoplastics
The intrusive method of forming products consists in the fact that the plasticization of the product and the injection of the material are combined. In this case, it is possible to obtain castings with a larger volume than the nominal injection volume.
PRESSURE CASTING PLASTIC: PRODUCT TECHNOLOGY
Formation of products on plunger-type machines
In injection molding machines of the plunger type, the formation of products allows minimizing the destruction of the glass fiber filler, which will provide high strength of products. In this case, the injection rate will be determined by the heating of the material in front of the piston. The disadvantage of this method is the loss of pressure between the piston, which injects the melt, and the gating system. These machines also have additional feed and metering cylinders.
Formation of products on worm-type machines
This plastic injection molding technology has become more widespread and marked the advancement in injection molding technology. The process begins with filling the plasticizing cylinder with solid material, which is then heated. The material is in a viscous-flowing state, after which the heated material is injected into the mold. Further, the material solidifies in the mold and at the same time the next portion of the material is prepared.
The big advantage of this method is the ability adjust the filling speed of the plastic injection mold. When choosing a method of molding plastic products to order, be sure to consult with professionals. Contact KLONA for detailed information on plastic injection molding.
TYPES OF GATE SYSTEMS
Application of cold runner systems
Such a scheme for the production of plastic products allows you to maintain the required temperature in the channels (thermostatting). This ensures the fluidity of the melt and prevents its premature solidification in the central gating channel. After the material has hardened, it can be easily removed. This process is characterized by high stability.
Hot runner injection molding of plastics
In this version of injection molding, central and distribution gates are not formed due to the fact that the material in them does not solidify. Temperature control in the runners prevents the material from hardening during the forming cycle. The remaining material can be used in the next casting cycle. This allows save costs on sprues due to the fact that they simply do not form, which is very important for large-scale production.
We have our own production of plastic products in Ukraine. Order the entire production cycle of a plastic product from KLONA – from mold modeling to the injection of plastic bodies on our injection molding machines.