Advantages of using precision molds in plastic production

Using precision plastic injection mold in plastic production, also known as plastic injection molding, or plastic injection is of great significance in production. This is considered the most widely applied plastic manufacturing technology in the world. Let’s find out their advantages in the article below.

1. The plastic injection mold of fast production

To produce a complete plastic product, the initial plastic injection process requires a considerable amount of time to order, arrange, and install all the things to start operation. The injection molding cycle in production is greatly influenced by the plastic injection mold.

Multi-cavity plastic injection molds are made to produce small to medium parts, thereby shortening production time will contribute to increased output.

Adjusting injection molding parameters settings

Precisely manufactured molds are crucial for adjusting injection molding parameters settings. These molds will be easy to achieve the desired operating parameters of the production unit.

Using precise molds in production is the basis for accelerating the process of mass production of products, contributing to improving productivity and quality.

2. The plastic injection mold of high accuracy

Plastic injection mold technology is considered a production process with high precision. Therefore, the manufacturing of plastic injection molds brings great value. Moreover, Injection molding technology is increasingly being applied in creating products common in such fields:

• Automotive,
• Machine Building,
• Aerospace Technology.

The finished plastic injection molded product will have extremely high accuracy, only approximately 0.001 inch (0.02mm).

The quality of injection molded products is highly durable

The quality injection molded products are highly durable, running for many years with millions of injection cycles without deformation, a product of the last cycle with the first cycle product of uniform quality. There is not even a tiny difference.

Injection molding technology can easily create products with complex shapes perfectly.

3. Minimizing production costs

The production method of using precision plastic injection mold, which greatly reduces the cost of the production process,  is becoming more and more popular because of the apparent effects it brings.

Precision molds increase the performance of machine systems, thereby cutting labor costs. According to the actual calculation, only one worker needs to carry out the product packing inspection for two injection molding machines.

On the other hand, highly automation produced goods with stable quality, reduced defects, high output rate, which is the most effective way to reduce production costs.

4. Flexible production of plastic injection mold

Each plastic product with a different shape, size, and product characteristics will require the use of different types of molds. Also, a plastic injection machine is a fixed production machine, there is almost no change, and plastic injection mold is considered a mobile tool.

This change depends on the plastic injection mold project.

Using precision molds in production allows professional plastic injection companies to receive multiple orders from different customer sources. Manufacturers produce products that are cheap but still ensure safety, quality, and reliability. From there, it brings a lot of economic values, which are the foundation in promoting the development of the company.

5. Reduce plastic waste with plastic injection mold

In addition to high accuracy and high productivity, using plastic injection molds in plastic injection brings an apparent change in significantly reducing the amount of plastic waste into the environment.

After each injection molding cycle, all remaining plastic is to create new products following the requirements and required characteristics.

The mold-making process always involves carefully calculating all factors, including the amount of excess plastic after each injection molding cycle.

Tip-Top Molds is a diverse processing manufacturer of plastic

Tip-Top Molds is a diverse processing manufacturer of plastic molding products from small to large quantities, ensuring full quality, prestige, and affordable price criteria. Furthermore, if you are looking for a precision mold-making partner in plastic production, please contact us for the fastest advice.

Plastic injection molding machine is one of the technologies applied to plastic production because it can produce millions of products while keeping uniformity. This comes with the increasing demand for plastic products.

Moreover, plastic manufacturers have imported varieties of models of machines to meet. In this article, we will learn more about the structure and operating principle of the machine.

What is a plastic injection molding machine?

Plastic injection molding machine, also known as glue press. An injection molding machine is a machine commonly used in the production line of plastic bottles and jars. Moreover, the machine’s main use is to fix the closed mold during the process of pushing the molten plastic by injection pressure into the mold core. 

At that time, the plastic will fill the mold cavity and open the mold when the plastic product has cooled.  Currently, there are many types of machines with all different designs and models. 

They are classified based on the following factors:

• According to the axis
• The Working principle of mold
• The Structure principle (hydraulic, electric)
• According to the size of the plastic injection machine

Depending on the type of plastic injection mold, design, and size of the product, the user will choose the appropriate machine. Currently, modern machines match many types of products. One machine can be common flexibly for many different types of products.

The general structure of plastic injection machine

The plastic injection machine consists of 2 main components: plastic injection part and mold clamp part.

Mold clamp part

This is an important part, including the movable mold clamp and the fixed mold clamp. In there:

The fixed mold clamp has the main task of clamping and keeping the mold fixed. As a result, the mold will always stay in the correct position thanks to the positioning ring on the mold and the positioning hole. 

The movable plastic injection mold clamp has the main function of clamping the movable side of the mold. This part will move in a direction parallel to the opening and closing direction of the mold during the injection molding cycle. 

At the same time, it arranges with a push-pull to help effectively impact the battery ejector plate when pushing the product out.

Conclusion

This is the component that uses heat to convert the plastic from a solid to a liquid form. Then, the liquid plastic part pushes into the mold set through the nozzle pressure system and the screw.

In addition, the structure of the machine will include some other parts: a cooling system, a support system, etc.

System of plastic injection machine

Currently, the system of the custom injection mold will be divided into 2: the basic system and the injection molding support system.

The basic system includes: 

• Clamping system
• Spray system
• Mold system
• Injection molding support system
• Control system

Injection molding support system includes:

• Machine body
• Power system
• Hydraulic system
• Cooling system

Classify

To classify, we need to be based on several factors: axis, size, structural principle.

Sort by axis

• Vertical press machine
• Horizontal press machine

Classification according to the operating principle of the mold:

• Molding Machine
• Plastic custom injection mold
• Plastic laminating machine

Classification by structure

• Water pressure machine
• Electric press machine
• High-frequency press machine

Sort by size

• Large presses (100 tons and 150 tons, 200 tons, etc.)
• Mini injection machine (Mini plastic injection molding machine and manual mini plastic injection molding machine)

The operator operates a custom injection mold maker

A plastic custom injection mold has the same operating principle as an injection pump. First, the plastic will be put into the storage hopper. Then, they will be liquefied by the heating rod at the appropriate temperature. Next, the entire liquid plastic will move forward thanks to the screw. 

At the same time, the screw will move backward to create space for the plastic to flow into the front of the nozzle. Thanks to the thrust of the screw, the hot plastic will be molded. Finally, the cooling system cools the product before taking it out.

Uses of plastic injection machines

Plastic injection molding machines are used to create plastic products of various textures and shapes. They allow creating products with absolute precision compared to the design. In addition, you will make many products in a short time. 

For simple details, in 1 minute, you will create about a few dozen products. Product quality is uniform, with no condition, distortion, breakage, or deviation from your design.

Custom injection mold knocks out conventional packaging and bottle manufacturing methods. When using, one thing is sure: the aesthetic value of the product will be guaranteed. Moreover, it also helps to save significant costs for businesses, promoting strong development.

Installation and repair instructions for plastic injection machines

Usually, the machine will be quite large. Therefore, you should prepare a large space to place the machine. In addition to the size and weight factor, the installation of the machine is quite simple. Most of the time, you will only need a stable power source and a large enough space to place the machine.

As for custom injection mold operation, you will find it challenging to do this job if you do not have too much experience. Usually, there will be one user manual for customers when buying the machine. However, you should have a team of technical staff with experience in this field to facilitate the operation and maintenance of the machine.

The mold assembly of custom injection mold 

It is considered the most important step in the mold-making process because any error in the assembly process will directly affect the quality of the product. So how to make the process take place most effectively? The following article will introduce you to the following 11-step process.

What is the mold assembly process?

This is the process of joining together the parts in the mold after machining. Each set of molds will have a lot of parts that you will need to assemble. Therefore, the first requirement of every mold assembly worker is to be able to read mold blueprints. Because only then will they be able to conduct the correct assembly and shape the product.

Different types of custom injection molds

Currently, there are many different types of custom injection molds. They are classified according to the structure. It can be 2-layer mold, 3-layer mold, multi-layer mold. The 2-stage mold is the simplest type of mold. You can complete the assembly work in a short time. As for other types of molds that include a combination of many parts.

You will need experience in the field of mold making and the ability to read blueprints. Therefore, the time to finish this type of mold will take more than the 2-plate mold.

Mold assembly process requirements

For the mold assembly process or any manufactured product, technical requirements are always the premise for the manufacturer to rely on to contribute to creating the best quality molded products. Here are some key technical requirements in the process:

• Determine the exact number of parts in the mold set
• Define the correct process. At this stage, the technical department will print the design and send it to the assembly department. The job of the assembly department is to be able to accurately read and understand every detail.
• Master the parameters and procedures.

Steps in the mold assembly process

To complete assembling a complete set of molds, you will need to complete the following 11 steps:

• 1: You will need to determine the number of mold plates and import the mold plates into the model
• 2: Install guide bearings on the upper mold plates
• 3: Install the clamp plate with the upper mold plates
• 4: Install the spray stem silver to the upper clamping plate. At the same time, you need to install bolts to fix the two mold plates.
• 5: Install the mounting bolts to fix the positioning ring and install the positioning ring with the clamp plate
• 6: Install the guide pin on the bottom mold plate
• 7: You will need to install the ejector plate to the mold set
• 8: Install enough springs and two supports
• 9: Install nine return latches and fix plate
• 10: Proceed to install four bolts and a push plate to create a connection between the push plate and the retaining plate.
• 11: To make the movable part link, you need to install the top clamp plate and four bolts.

The process of disassembling the injection mold

To disassemble the mold, a special tool kit will be needed.

1: You will need to remove the main plates of the mold

2: Disassemble the focus injection system from the fixed plate

3: Remove the ejection system from the mold and proceed to disassemble the details of the ejection system

4 Common Errors in the plastic injection process, causes, and solutions

Contacting a custom injection mold supplier can save you from many project issues. Many defects can form on the finished plastic product. In this article, we will discuss all the common errors in the plastic injection process, their causes, and how to fix them.

Common mistakes in the plastic injection process

There is a lot of room for costly mistakes when it comes to the injection molding process. Quality problems in injection molded products can range from minor surface defects to more serious problems affecting product safety, performance, and functionality. 

How to get high-quality plastic injection mold

The quality of the plastic custom injection mold supplier is equally important to the molding process. The injection molding company you choose to help you manufacture your product overcomes common mold problems.

When you have a high-quality plastic mold plus a good injection molding process. This will yield the expected results from the final product. Plastic injection molding is a common way to produce all kinds of items. It can be like garden tools, electronics, kitchenware, etc.

Components are easy to make from

• Glass,
• Polymers,
• Metals,
• Plastics, etc.

Working on high-quality molds is the only way to ensure high-quality molded parts.

Common errors in custom injection mold supplier

Common errors are easy to be caused by the type of raw materials common in the plastic injection process, the quality of the plastic mold, the skill of the workers in the injection molding process, the injection molding machine, etc.

Fortunately, the treatment and prevention of common injection mold is also important. And using these methods, manufacturers can make high-quality custom injection molds, because if you make a high-quality mold, all other problems are easily solved. Understanding what defects and what causes them is the first step to ensuring that products developed in the process consistently meet acceptable standards. 
Defects can reduce the loss incurred 

These defects can reduce the loss incurred because of unsold products or defective products returned after the sale. Let’s look at the most common injection molding errors, what causes them, and what you can do to fix them.

Common mistakes in the plastic injection process

Possible defects due to process failure

Sometimes the problem is not with the raw materials or tools common in the process, but with the injection molding process itself. Once you are sure that the defects are caused by the process, all you need to do is adjust certain important factors like wall thickness, which are easy to avoid.

1. Line Mark

Line lines (also called flow lines) are waves, streaks, or lines that change color compared to the area around them.

These are visually visible near the ‘gate’ points or gate locations of the custom injection mold where the molten plastic enters and through the injection molding process. They do not affect the functionality of the finished product but are irritating, especially when found on cosmetic products.

Reason:

The flows are due to the change in the cooling rate of the molten plastic as it flows through the barrel and the mold is heated and solidified. This also happens if there are thin walls and thick walls instead of a uniform wall thickness because the material cools at different rates.

Slow injection rates or low-pressure injection molding can also cause flows, as the plastic cools very quickly and becomes thicker, forming molding defects such as patterns or wavy streaks.

How to fix custom injection, mold supplier:

• Increase injection speed, pressure, and material temperature to ensure the material fills the custom injection mold before cooling
• Rounding mold corners where wall thickness increases to help keep flow rates consistent and prevent flow
• Relocate the mold gates to create more space between them and the mold coolant to prevent the material from cooling too early in the melting process.
• Increase nozzle diameter to increase the flow rate and prevent premature cooling 
• Applying lubricant to the surface will also aid the flow of molten thermoplastic material in the running system.

2. Burns

Burns are dark marks on the edges or on the surface of the molded part produced by a custom injection mold, which is not part of the product design. They are usually harmless unless they burn causes the plastic to decompose.

Reason:

The most common cause behind burn marks is air bubbles or resin trapped in the mold cavity that overheats during the cycle. This may be due to high injection speed or material overheating.

How to fix Burns:

• Lower the melting point and mold temperature to avoid overheating
• Reduce injection speed to limit the risk of air trapped inside the mold
• Widen the air vent and outlet to allow trapped air to escape from the mold
• Shorten custom injection mold’s cycle times so trapped air and plastic have no chance of overheating

3. Warping

Warping occurs when different parts of the product cool and solidify unevenly during plastic processing.

Reason

The main cause of warping in plastic products is the premature cooling of the material. This may or may not be due to overheating and the absence of uniform mold walls.

How to fix:

• Ensures cooling slowly and long enough to avoid uneven stress on the material
• Lower the temperature of the material or custom injection mold
• Try switching to a material that shrinks less during cooling (e.g., granule-filled thermoplastics shrink much less than semi-crystalline or unfilled ones)
• Redesigned mold with uniform wall thickness and part symmetry to ensure more stable part during cooling

4. Vacuum/air bubble

While not considered a major defect, it can lead to a deterioration of the product during product development.

Reason:

One of the most common reasons for vacuum voids in plastic products is insufficient pressure in the mold during low energy production. 

How to fix Vacuum/air bubble:

• Increase injection pressure to push out trapped airbags
• Choose a material with a lower viscosity to limit the risk of air bubbles forming
• Place the gates close to the thickest parts of the custom injection mold to avoid premature cooling where the material is most susceptible to voids