Injection of plastics into silicone molds – production technology products in small batches, (from 20 to ≈300) by casting parts in a vacuum.
By choosing the method of molding plastics into silicone molds, you get a complete copy of your product or its model. Also, casting plastics (and their varieties – polyurethane) into silicone molds gives quick results at a low price (compared to plastic injection molding).
How much does it cost to mold plastics into a silicone mold?
The cost of small-scale production of parts using the technology of molding plastics into a silicone mold depends on:
- the number of parts required;
- product dimensions;
- materials of manufacture;
- the complexity of the geometry of the product.
- The price for all the preparatory steps, the creation of the silicone mold and the casting of one product begins from 15,000 hryvnia.
The KLONA company is engaged in custom molding of plastics. To calculate the cost of your project Contact us, by writing in the window in the lower left corner or by mail.
SMALL-BATCH PLASTIC PRODUCTS AT CLONE: ADVANTAGES WHEN ORDERING
The shortest possible production time
The process of manufacturing products using the technology of molding in a silicone mold takes much less time than making a injection mold and is cheaper.
This makes it ideal if you need to make a small batch of products in a short time.
Personal control of the manager at all stages
A feature of the KLONA company is an individual approach to each client and order. Working with us, you will be able to control the entire course of work.
The manager who will lead your project will answer all questions and will be constantly in touch.
Optimum finished product quality
Thanks to the latest equipment, high precision of the finished product obtained by vacuum casting into a silicone mold.
Low cost compared to other production methods
For the manufacture of a small batch of plastic cases, it is worth choosing this particular technology. For the manufacture of a small series of parts you will need less equipment (compared to injection molding).
The more parts you need to produce, the more materials will be used for this, respectively, the price will be higher. This also applies to product dimensions and complex geometries. If you need to manufacture a large number of plastic enclosures or require large and complex products, other manufacturing options (such as injection molding) are worth considering.
If you need individual small-scale production of enclosures or plastic parts – contact KLONA. Plastic masterpieces are created here!
CUSTOM PLASTIC CASTING: TECHNOLOGY FEATURES
Molding of plastics into silicone molds opens up ample opportunities in choosing the shape and color of the product, its hardness and the type of surface (matte or glossy).
Plastic – inexpensive, sufficiently durable and functional material … Therefore, vacuum casting of plastic products is popular in Ukraine.
The manufacturing process consists in pouring the liquid components of synthetic polymer compounds into silicone matrices. This takes place in a vacuum space, so that air bubbles do not get inside the product.
After the end of the casting process, the plastic is hardened. By using the silicone molding method you can get both hard and elastic objects …
Small-scale production of parts is used for creation of small batches of products. For example, the manufacture of plastic cases for various technical devices.
The CLONA company was engaged in manufacturing of plastic cases for the switch within the framework of a joint project with INVEX Telecom.
STAGES AND FEATURES OF SMALL-BATCH PRODUCTION
Creation of a 3D model of a future product
For the production of high-quality silicone molds and the production of plastic enclosures you need a 3D model. It can be created by KLONA modelers (using photographs from different angles, drawings, technical documentation, sketches and sketches of the product, text description).
You can use an existing 3D model (if available). It may need some work. There is also a possibility use the finished product and create a 3D model in its image. It is possible to create an exact copy of the product or improve it.
Production of a product prototype
Most often, a prototype is made by 3D printing (in rare cases, a prototype can be made using a milling machine).
After prototyping a product, you can evaluate its functionality. If you find any shortcomings, make changes to the model.
Making a master model
After printing the prototype, minor rework (grinding) may be required. Next, the preparation for the casting of the silicone mold is carried out.
This process includes:
- applying adhesive tape to the future mold release line;
- gluing all holes with adhesive tape, and if the grooves and holes are too deep, they are reinforced with metal elements;
- it is also possible to apply additional compositions to obtain textures (for example, shagreen).
A fully refined prototype is called a master model. It is he who is used to make a silicone mold.
Making a silicone mold
To create a matrix (shape), a commensurate product is made formwork – the container in which the product is placed. The formwork material must be hard enough to maintain its shape after being poured with silicone.
Further inside the formwork the master model is placed, and the gating system is installed (tubes through which plastic will be fed into the silicone mold).
Then the silicone mixed with the hardener is poured into the formwork. Before pouring, the silicone passes degassing process in a vacuum chamber. The container with silicone is placed in a special degassing chamber, where it solidifies. After the end of the hardening process (it lasts about 24 hours), the master model is removed and a ready-made matrix-form is obtained.
Vacuum unit – a machine in which a two-component compound is mixed before pouring into a silicone mold, thanks to this unit, plastic under low pressure conditions fills the entire mold without leaving voids and air bubbles … This allows for the production of high quality plastic cases, parts and figures.
The casting is needed to check the shape and evaluate the results of the work done …
Refinement of the form
If, after a test casting of a part or body, the resulting product differs from the master model, you need to modify the shape. This is very an unlikely situation with a low degree of realism.
However, if necessary, the form can be modified, it does not take much time.
Small batch production launch
After a successful test casting (initial or after finalizing the mold), small-scale production is launched.
To do this, a certain number of forms are calculated and created that will be required for the manufacture of a batch of products (based on the fact that one silicone mold can be used about 20 times).