What are Injection molding machines?

Injection molding machines are over-molding plastic on metal designed for injection molding of serial products from polymeric materials.

Mini injection molding machines allow the production of various batches of precise small parts of any complexity from polyurethane, polystyrene, polyester, polyamide, and other thermoplastic polymers.

However, a large assortment of mini injection molding machines of the SS series, for molding small-sized products. In addition, the over-molding injection molding machine has proven to be a reliable and efficient plastic injection molding machine.

Advantages of over-molding plastic on metal

Mini horizontal injection molding machines for molding small-sized products of the SS series deliver in a ready-made package. Moreover, the mini injection molding machine meets international quality standards and has a number of advantages:

• Impeccable build quality;
• Reliability and stability of work;
• High performance at low energy costs;
• The ability to work in automatic and semi-automatic modes;
• Availability of reliable protection systems;
• Purity and safety of production;
• Ease of maintenance and quick changeover;
• The ability to quickly change molds;
• Minimal vibration and noiselessness;
• Affordable cost of injection molding machines, spare parts, components, and consumables;
• Suitable for various types of molds and different types of material;
• The ability to work from the network 220v.

The injection molding machine provides a high mass heating rate

In the over-molding plastic on metal, the heaters locate close to the material. Thanks to the small-sized injection molding machines which provide a high mass heating rate, which significantly saves energy resources.

In addition, all parts of the mini injection molding machine are highly reliable and have a significant margin of safety. Moreover, the small-sized desktop injection molding machine has a small size that does not require large production areas.

The mini injection molding machine: Peculiarities

Distinctive features of the mini injection molding machine increase productivity, high dosing accuracy, and joint operation of all units.

However, in over-molding plastic on the metal of the series, instead of plungers, the melt mixes by screws, consisting of a torpedo and a retaining ring, which allow the mixing of the melted mass with the highest quality.

The mini Injection molding machine can operate on 220V.

When choosing injection molding machines, the following indicators should be the determining factors: the distance between the guide columns, the forces required to close the injection molds, the injection pressure indicators. 

Moreover, the dimensions of the maximum molds installed on injection molding machines depend on the distance between the columns.

Requirements for environmental safety

The production of products and the quality of raw materials for over-molding plastic on metal are subject to increased requirements for environmental safety standards.

Moreover, the choice of injection molding machine should base on the tasks that can solve with the help of injection molding equipment.

Mini injection molding machine series: Specifications

The mini injection molding machine series represents a wide range of models of injection molding machines for the production of various plastic products with different technical characteristics. Moreover, the most significant of them:

• Motor power ranges from 3 KW in the SSF 320 injection molding machine to 13 KW in the SSF 1200 injection molding machine;
• A clamping force from 320 KN to 1200 KN;
• Each model of injection molding machine has the ability to install two or three auger options with different rotation speeds and different maximum injection pressures;
• Different injection speeds, from 25-32 grams/sec in SSF320 to 89.105 and 128 grams/sec in SSF 920;
• The minimum melt injection volumes are 30 cm3 for the SSF 320 and the maximum 158 cm3 for the SSF 900 and SSF 920.

The servo drives ensure high stability and precision

Injection molding machines mini-series SS start closing the mold simultaneously with the start of injection of the molten mass, gradually increasing the force. Moreover, mold clamping units of over-molding plastic on metal provide full automation of the production process and greatly facilitate and shorten the process of manufacturing parts.

The injection molding machine has good rigidity

Despite the rather lightweight desktop injection molding machine, the injection molding machine has good rigidity due to its reliable and durable frame. However, the special design of the screws ensures the high quality of the prepared melt.

The automatic control system doses the injection volume with high precision and regulates its speed. Moreover, multi-stage control of all stages of production ensures the stability and absolute accuracy of the linear dimensions of small-sized products.

Application areas of over-molding plastic on metal

In addition, the wide possibilities of the equipment allow the use of a mini injection molding machine in any field of industry, mechanical engineering, medicine, companies in the production of furniture, electrical products, toys, and other plastic parts.

Moreover, on horizontal small-sized injection molding machines, it is possible to manufacture parts for various purposes:

• Furniture fittings and components;
• Accessories of plastic windows;
• Parts for medical devices and equipment of varying complexity;
• Stationery, souvenirs, toys, etc.;
• Various kitchen utensils.

Moreover, mini injection molding machines are designed for micro-molding of small batches of plastic parts.

Injection molding machine for micro-molding

Over-molding plastic on a mini metal of any model consists of the main components:

• Plasticizing unit, which includes heated cylinders and screws. This is the preparation unit where the raw material enters, melts, and moves into the molds. Moreover, the design of the unit ensures high accuracy of dosing and preparation of the polymer mass.
• In addition, a clamping unit operating under the action of a toggle mechanism or hydraulics is used to mold plastic products;

However, electric motors of injection molding machines ensure the operation of hydraulics that drive the elements of the injection molding machine.

Injection molding machine: The hydraulic system

The hydraulic system includes control valves, pumps, cylinders, and drives for ejectors of finished molded parts from injection molds.

Moreover, through the over-molding plastic on metal automation system with a touch screen, molding parameters and modes are set, heaters, drives, and all molding processes controlled:

• The temperature regime of the cylinders is set for the preparation of raw materials for injection;
• Injection pressure, speed, dosing of polymers, and holding time are set;
• Distances of movements of pushers regulate.

Moreover, over-molding plastic on metal consists of a movable plate and a fixed plate. In addition, when the plates close, cavities form between them, into which the molten hot mass injects under high pressure.

Control panel for injection molding machine

To choose the most suitable over-molding injection molding supplier for specific purposes, you need to know its characteristics. The clamping force is important. With its help, you can get an idea about the options and dimensions of the equipment.

Plastination and injection unit of the molding cycle

This part is the main one in the whole molding cycle. The plastination and injection unit melts the thermoplastic and feeds it into the mold.

Step by step operation of the device:

• Place the material into the hopper;
• Further, the material is fed into the material cylinder;
• Moreover, the screw rotates and transfers it to the nozzles;
• Plastic heats up and melts;
• Similarly, plastics are injected into the mold.

Over-molding injection molding supplier: Cycle stages

Moreover, the casting cycle carries out in several stages of different duration:

• a) Closing the mold – Moving the injection unit forward – Feeding into the forming cavity;
• b) Pressure treatment;
• c) Movement of the injection unit back – Plasticization – Return of the screw;
• d) Opening the mold to extract the part.

Most of the time is spent working under pressure and cooling the part. Moreover, as a rule, the duration of these processes depends on the thickness of the walls of the product. Machining parts with thin walls takes more time in the dry cycle.

Closing and injection: to maintain the desired speed

The first stage is divided into several parts with different injection speeds. Moreover, it is possible to maintain the desired speed of the passage of plastic through the mold runners.

The auger maintains the material injection pressure

In the second stage, the auger maintains the material injection pressure. If the pressure exceeds the desired values, the parts of the mold will move apart, and the material will flow into the slots.

Plasticizing: the material is fed into the screw cavity

At this stage, the auger rotates and returns to its original position. Simultaneously with this process, the next portion of the material feds into the screw cavity.

Mold opening: the product is removed from the mold

The product cools in the mold, then the movable plate moves away, revealing the part formation cavity. As a rule, the equipment is designed to remain the product on the mold when it opens– the movable half. The product can be removed from the mold by pushers driven by a hydraulic cylinder of the machine with a shank.

For many years, our company has been manufacturing molds of various complexity for the production of plastic parts, which are produced by injection molding, using modern technologies that combine the use of the best components from world-famous manufacturers with the latest engineering solutions.

Over-molding injection molding supplier: calculating the cost

The mold production process begins with a competent technical assignment, that is calculating the cost, which is given to us by the customer at the stage of calculating the cost of future toolings. Moreover, competent terms of reference guarantee the accuracy of execution, as well as the receipt of a personalized product that will satisfy all the requirements.

Allows the Customer to receive a comprehensive service for 3D modeling

We can not only manufacture molds but also calculate the geometry, strength, light reflection, and transmission. This allows the Customer to receive a comprehensive service for 3D modeling of the over-molding injection molding supplier with the involvement of our designers.

Often, clients come to us with a visual representation of a future product, either a textured sample or 2D drawings. Moreover, in such cases, our designers themselves will develop a three-dimensional model of the product for the subsequent design of the mold.

At the development stage, the customer needs to specify as accurately and in detail all the nuances of the future product, geometry, properties, material used, surface, performance requirements, and so on.

The more details about over-molding injection molding supplier

Less time will be required for subsequent approvals and refinements of the mold design.

Moreover, we will proceed with the mold design. Here we take into account the requirements for productivity, ease of maintenance of equipment, and other important points that directly affect the life cycle of the product and its cost.

We acquaint the customer with the received drawings of the mold, who makes his own changes or approves the future design of the mold.

Moreover, after the design of the tooling is approved by the customer, the purchase of components and materials for the manufacture of the future molds will begin.

Heat treatment of molds

The inserts are placed to increase the wear resistance of the forming cavities. For example, a molding machine made of raw steel allows you to produce no more than 100,000 closures, and a heat-treated one allows you to increase the resource to 3 million. Moreover, not all steel can be heat-treated, for this purpose we choose special tool steel with a high content of carbon and alloying elements.

The process of finishing milling and electro-erosive machining

Finishing milling of hardened steel carries out in over-molding injection molding supplier using special carbide cutters at high speeds. For electro-erosive machining (piercing), a copper electrode uses, which burns out the required geometry of the forming cavity. Next, the molds will be polished.

In parallel with the process of manufacturing the molded parts, the mold package is machined. This process includes casing milling, backing plate milling, cooling channel milling, etc.

Assembly: pre-test the mold on an injection molding machine

Moreover, all parts transfer to the assembly shop, where workers assemble and pre-test the mold on an injection molding machine.

Testing: for adjustment during commissioning

The mold securely attaches to the clamping plates. After which all parameters are set, followed by a test injection of the material into the cavity. During testing, the molding card issues should be paid attention to. This is subsequently sent to service engineers and the Customer for adjustment during commissioning.

Based on the test results, test samples send to the customer to check the geometry and approve textured samples. Moreover, according to the results of the comments received, the molds will finalize with the subsequent shipment.

In conclusion, after signing the certificate of approval of the received samples, the molds will be preserved by applying grease and packed in wooden boxes for subsequent transportation to the customer.

The plastic industry is one of the most present in our daily lives. For the proper functioning of the cycle, it is important to choose an injection mold.

About the injection mold

One of the characteristics that makes plastic so widely common is its gigantic molding capacity. Thermoplastic polymers can, under conditions of temperature and pressure, be suitable for any shape. One of the methods of doing this is through injection molding machines.

In the molding machine, the raw material is melted, injected into a mold under high pressure, and after cooling, comes out in the desired shape. While this process is fast, it is not continuous. It is cyclical.

The big difference with the injection mold

The extruder is capable of generating continuous products. The screw, present in the equipment system, rotates and sends material to the die constantly. The parts produced are subsequently cooled, while in the injection molding machine this process usually takes place inside the mold.

The feeding of the machine: occurs through a hopper.

After passing through this hopper, the granules are sent to a screw that takes them to a cylinder, where they are heated through electrical resistance.

Here we have 3 phases in the injection molding process: feeding, compression, and dosing.

• In phase 1, feeding: the granules heat until almost reaching the melting point.
• stage 2, compression: the material presses against the cylinder walls until it becomes plastic.
• In phase 3, dosage: the moment when the material mixes and the flow carry out.

The great difference in the use of the plastic extruder is its productivity. Mainly due to the continuity of the process.

In the manufacture of injected parts for the most diverse purposes, painting and finishing are fundamental processes. By painting injected plastic parts, it is possible to brighten the surface, hide modeling flaws, and provide extra protection.

Injection mold: top plastic parts

Plastic parts are common in the most diverse products, being part of our daily lives at different times. The injection of thermoplastics makes it possible to mold the polymers so that they take on the desired shapes. Having the expected format is a big step, however, it is not enough.

Other features form the products. Among them, the color, which is in the injected parts, defines through the painting process.

There are currently two major trends in painting plastic parts. Discover both below.

Electrostatic painting: the principle of repulsion and attraction of charge

This type is better when the goal is to create a long-lasting, even finish. It is based on the principle of repulsion and attraction of charge. Although widely common on metallic materials, it goes well with any electrically charged material. Even in injected parts, as long as a pre-treatment is carried out to allow the ink to adhere.

Texturing: becoming increasingly common

In painting plastic parts, the texturing technique is gaining a lot of supporters and is becoming increasingly common. It makes the pigmentation of the plastic piece eliminated so that it can be painted in any color. Texturing recognizes for offering a superior finish, even enabling color and metallization.

However, it is important to highlight that the textured piece needs to have a homogeneous painting, which means that there can be no process changes or ink build-up.

Which processes depend on the objectives of the product?

The thermoplastic injection is a production process widely common in different industries.

Moreover, this is due not only to their efficiency but also to the great versatility of the injection molds, which meet different needs. And as the year goes by and new materials and techniques develop, this scenario only increases.

Material mixing and thermoplastic injection

One of the industries that uses the most of the thermoplastic injection process is the packaging industry. This, in turn, has found an increasingly demanding market.

The growing trend towards multilayer solutions

It is necessary to count on materials that present great resistance. But also, injection molds are capable of preserving the characteristics of the products. In addition to the development of new materials for monolayer thermoformed boards and films, there is a growing trend towards multilayer solutions. These solutions can unite and combine different raw materials, such as:

• Polyamide(PA);
• Polystyrene(PS);
• Polyethylene(PE);
• Polypropylene(PP);

Different polymers lead to more sophisticated characteristics

The use of this option has been highlighted especially in the production of packaging for the food industry. Moreover, with the pressure for a healthier diet on the part of society, there is a decrease in the levels of fats, sugar, and preservatives. Injection molds affect the durability of the products.

In addition, there is a search for more sustainable materials for packaging, as well as those that are light and keep the food warm or even that can withstand place in the oven or microwave. Moreover, the combination of plastic materials, taking advantage of their characteristics, is another example of the strength of this industry.

 

The process demands high standard requirements

The process makes it possible to meet diversified demands and high standard requirements. The injection mold stands out in the use of this process, but many other industries also benefit from the procedure.

For this, of course, it is necessary to know the needs and objectives, allowing making a customized solution.

One of the main differences that we can notice is in the equipment common. They are made from injected plastic, from the light holder, toothbrush handle, dental floss packaging, among others. Moreover, these make the professional’s job much easier as they are lighter objects.

Provides more comfort to the patient

Even the dental office has a large number of its structures in plastic, such as the arms chair for rest.

Moreover, some of the common injection molded parts are as follow:

• Protective glasses and visors;
• Ear protectors;
• Beds and saliva suckers;
• Plastic barriers in instruments with motor, syringes, among others.