Why are plastic injection moldings important today?

Injection mold maker in China can produce different products common in our daily lives in objects such as remote controls, appliances, children’s toys, etc.! But have you ever wondered how the plastic injection molding process is carried out? Now we will answer your question!

Molding performs using a molten material, which can be glass, metal, rubber, plastic, etc. A mold fills with this material under pressure and then cools, thus causing plastic molding.

In this article, we are going to talk about plastic injection molding, so the common molten material is plastic resin.

History of the first injection mold maker in China

The first plastic injection moldings were carried out in the early 1870s, producing billiard balls. Later, this technologically advanced and the new product could be developed.

This process involves different elements of our daily lives. Plastic injection molding produces from cups and children’s toys to military and automotive products. To know everything about this subject, follow our article!

How does injection molding work?

As stated earlier, this process uses a molten material to create the molds. In the case of plastic injection molding, the plastic resin is common, which is initially melted until it reaches the molten state.

The raw material is pulled into the machine through a hopper, using gravity to feed the material. Afterward, the material passes into a cylinder until it reaches the heater so that it leaves the solid-state for the melt.

Soon after, the material is injected through a nozzle under pressure, which directs it to the mold, which is subjected to high pressure, and from there, the material cools to hard.

When hardened, the part removes from the mold. This process takes about a minute or less.

What are the main plastics common?

For many injection mold makers in China thermoplastics are the main ones common in this process. They melt easily at high temperatures and can be reheated more times.

In addition, they have properties that allow the use of chemical additives that change color and can color with glitter.

 

Discover the main common thermoplastics

Nylon: It is one of the main resins common for the manufacture of fabrics, food packaging, and automotive parts.

Polypropylene (PP): It is one of the main ones common all over the world. It has outstanding characteristics such as chemical resistance, flexibility, and insulation.

Acrylonitrile Butadiene Styrene (ABS): It is commonly common for applications that require a tough exterior and thermal stability. It is the thermoplastic that has the lowest cost.

HIPS (High Impact Polystyrene): Thermoplastic with high impact resistance and stability, generally common for signage. It can glue and can also receive the addition of products to change the final aesthetic, in addition to having low cost.

Polycarbonate: It is an alternative that has resistance and lower cost. It is naturally transparent, which allows its use in bulletproof glass and medical use, such as test tubes, beakers, and pipettes.

What problems can you face in plastic injection?

We know that in any process, there are certain disadvantages in not choosing the injection mold maker in China who really has a well-structured process. Now please see more info below:

• The initial cost can be high, so the importance of looking for partners who advise you on ways to reduce the costs of your molds.
• In order for precision and quality in the final result, it is important that you find the best specialists, as it is essential for the final appearance to be as expected in prototyping.
• Injection moldings can take longer lead time than other processes.
• Revisions in injection molds may not be easy to perform, as some details of the finished part may be modular, making changes impossible.
• An overhaul may require the creation of a new mold, which can jeopardize the project, incurring additional costs.

What are the main advantages?

Now that you know some disadvantages of this process, know the main advantages of plastic injection:

• Production in high quantity with an excellent cost-benefit. The implementation will be the biggest investment; however, the manufacture of the parts is carried out with greater optimization and quality. It can be dimensioned according to the needs of each client.
• Injection mold produces a low amount of waste, which contributes significantly to the environment.
• It has the possibility of using thousands of different resins, which have strength, quality, and durability.
• Consistency in products, if you need to produce the same part for a long time, injection molding allows for consistent repeatability – in addition to offering an automated and optimized process.

The repeatability of the idealized product

Injection molds are tools that aim to produce compact plastic parts, whether in thermoplastic or thermoset materials. They are good at large-scale production in order to guarantee the repeatability of the idealized product. Injection mold‘s structure allows the construction of one or several cavities, which will define the number of pieces per hour associated with the cycle time.

The greater the number of cavities and the shorter the production time of the products, the greater the production, thus it reduces their cost.

The cavity is the negative part of the mold

It is what gives the molded product its external shape. Its main function is to form the external (visible) part of the part, together with the core. It is the most important part of the mold. The cavities come of excellent quality steel. They are P-20 (benefited steel), H-13 quenched, and tempered with hardness between 48-50 HRc.

Male Cavity

The core is the positive part of the injection molds, with the function of forming the inner part of the product. The molded product has holes or slots normal to the injection direction, these shapes model on the core. The taps, like the cavities, come with the above-mentioned excellent quality steel.

Modern Plastic, Cavities extracted from the software by the students of the 3D Mold Design course.  

• Green: Matrix cavity
• Blue: Product
• Red: male cavity

Conclusion

In the male cavity, there must be extraction angles (product exit angle). The existence of this angle is of utmost importance. Hence, it is possible to release the product inside the cavity and also around the core. The software specialized in mold design has and provides tools for the analysis and rapid creation of this draft angle.

Your main plastic injection molding problems will be solved at Tip-Top Molds

Today, injection mold manufacturer in China has separated some solutions for some problems in the plastic injection that may happen in production.

Plastic injection is growing in different sectors, from the manufacture of children’s toys, remote controls, to the development of automobile parts and military equipment. Please find out more about it now! With the expansion of this market, the demands also increase, and, consequently, doubts may arise.

The common process of Plastic injection molding

Plastic injection molding is a process that is being common on a large scale by different industries. For your satisfaction with the result, it is necessary to find the perfect specialized technical team as your partner!

Injection mold manufacturer in China knows that developing new products and management strategies is not an easy task, so being aware of solutions aimed at practicality and quality is essential. Today, we have separated some solutions for some problems in a plastic injection that may happen in production and that we easily solve here.

If you came here looking for solutions to problems in plastic injection, please follow our article!

Main objections to plastic injection

Plastic injection is inserted in different branches. This technique makes molds for plastic parts that are common in many segments: office items, furniture industry, household products and utensils, toys, automobile parts, among others.

However, hiring an injection mold manufacturer in China is not an easy task. So please know the main objections raised that can hinder you in this choice:

• Low market commitment and lack of seriousness with the project;
• Lack of different solutions in one place, in addition to difficulties in solving eventual problems;
• Standardized services, without focusing on personalization and real customer needs;
• Companies that do not have their own tools or effective production control.

It is essential to be aware of these criteria when hiring a company as your partner! It is also worth mentioning that the injection mold manufacturer in China should use state-of-the-art technological devices and must follow technical safety norms and standards.

It is also worth mentioning that the injection mold manufacturer in China uses state-of-the-art technological devices and must follow technical safety norms and standards.

In other words, you must be aware that whether the contracted company follows these technical standards. If they do, then there are guarantees of product quality and safety for employees.

Responsible plastic injection companies

When an industry hires a plastic injection company, it must be responsible for developing the entire process that involves plastic in the manufacture of the developed product.

This company must provide efficient production, with precise and innovative items, so that they meet customer demand. The injection mold manufacturer in China must present the following aspects so that there is good progress in the manufacturing process:

• Precision;
• Quality;
• Productivity;
• Economy;

In addition to ensuring that there is efficiency for employees to handle machinery correctly, as well as a good investment in quality technological devices.

Confidence and guarantee of accurate results

It is worth mentioning that a plastic injection company must convey confidence and guarantee the customer accurate results.

Therefore, to avoid problems in plastic injection, it is necessary to hire responsible companies that clarify all doubts regarding the product and the manufacturing process.

Discover our factory and how we solved all this here

If you’ve come this far, I’m sure you could understand the importance of being aware of the main aspects involving the plastic injection process. Therefore, it is very important for you to hire companies that offer solutions.

Injection mold manufacturer in China has solutions for plastic injection problems

We have our own tooling. In other words, we can guarantee effective control of the entire manufacturing process, avoiding problems with plastic injection.

We carry out the entire process involving plastic injection: There is no need to look for different suppliers; you can develop the product in one place. Our services involve pad printing, ultrasonic welding, painting, chrome plating, assembly, and handling of specific sets and finishes.

Quality throughout the entire process:

With specialized technical assistance, we have a physical, chemical, and dimensional analysis laboratory. Systematic technical inspection of the production line with statistical process control, in addition to regular optimization of inherent process failures.

This guarantees quality by injection mold manufacturers in China throughout the manufacture of the product, avoiding problems with the plastic injection that you would have in other companies out there.

Specialized technical service:

Our services focus on the real needs of the customer, in addition to clarifying all doubts raised. We work with transparency and quality!

Do you want to know how we can help you throughout the production chain? Or do you have other plastic injection problems that you need to resolve? It’s simple: talk to us and we’ll help you solve them all.

The plastic market is one of the most important in the world, engaged in many fields. the production of packaging. Components and products are common in practically all sectors for injection mold manufacturers in China.

The revolution in the production of injection molding

The discovery of synthetic plastic in the first half of the 20th century contributed to the revolution in production and consumption recorded in that period. The material facilitated and enabled the development of many of the solutions common in everyday life, in industrial, agricultural production, and so on.

A proof of the material’s relevance to modern life is that today there are more than 400 million tons produced in the world annually. A number that continues to grow as polymers develop and gain new uses.

The great villains of the environment

In recent decades, however, plastic has been identified as one of the great villains of the environment.

Polymers are among the most difficult to decompose raw materials. A pet bottle, for example, can take 200 to 600 years to decompose in nature. This scenario raises the question…

Can the plastic market be sustainable?

The transformations that have taken place in the world since the industrial revolution has been massive and intense. Injection mold manufacturer in China has advanced so fast, and life expectancy has increased so much. We have had so much access to products and solutions, and, of course, we have degraded the planet so much.

The emission of greenhouse gases and their effects on the climate is just part of the socio-environmental problems. Humanity needs to face in order to maintain Earth’s conditions favorable to life.

The production of waste is also a serious reason that causes the environmental problem. Hence, it needs to be taken with the same seriousness that we now dedicate to the climate.

Increase in industrial production by injection mold manufacturers in China

With the increasing use of polymers in the production of parts, components, products, and packaging. They have become one of the main groups of waste that are discarded around the world on a daily basis.

In the last 65 years, of the 8.3 billion tons of plastic produced, about 6.3 billion tons were turned into waste.

Due to the difficult decomposition of the material when in nature today. Plastic waste appears as one of the greatest environmental risks. It is so severe that studies estimate that by 2050 there will be more plastic in the oceans than fish.

The good news about the plastics market and sustainability

The good news is that the material has unique characteristics. It makes injection mold manufacturers in China possible to turn this scenario around and make the plastic market part of the sustainable chain.

Plastic injection is simple, reliable, and very efficient, so injection mold-making companies use injection molds in the routine of industries and companies. However, this process requires experienced professionals in the market and a quality injection molding machine. Otherwise, the final result will not expect.

Discover the main benefits of using injection molds:

For the injection molds to take on their detailed shapes, high pressure will be on the plastics inside the molds. This force will make every detail of the piece come out perfect, exactly as it should be.

In addition to this precision in the details, with the pressure on the molds, it is still possible to give complex shapes. Some other processes would be much more expensive and would not have the guarantee of efficiency as in injection molds.

Agility without losing quality

Custom injection mold company designs and takes them to the presses duly pre-programmed, according to customer’s requests. From the beginning, the steps are fast, drawing attention to plastic production by injection. This agility makes the process more efficient and faster, thus increasing the production rate.

The molding process is reinforced by filling the molds

The molding process is efficient for a number of reasons, one of which is its strength, which can reinforce by filling the molds. With this technique, it is possible to reduce the density of the plastic at the same time it molds, so that it does not lose its shape.

For an injection mold-making company, the manufactured parts need to be strong and have greater durability. Therefore, plastic injection has this option since other molding processes do not provide the same resistance.

Several types of plastics in a single mold

The versatility of this process allows molds to produce not only with one type of plastic but with several simultaneously. To obtain this result, the practice carries out by co-injection molding.

Process automation

The entire plastic injection molding process is automated. Robots and machines can do the job, but an operator needs to control and manage these machines so that they maintain production efficiently.

As in any other area, this automation helps reduce costs without losing quality in the final product. This makes it easier to pass on reduced value to the injection mold-making company.

Finished parts right out of the machine

Once the parts are produced by injection molding, they will not need finishing or any other type of post-production. After being ejected by the machine, the part finishes in the desired design and is ready for use.

The environment

Although plastic is a topic in conflict with the environment, this process earns some points when we refer to sustainability. This is because the material used in the production process is reused, giving a new function to a product that would otherwise be discarded. As a result, injection mold-making company generates little waste.

The molding processes

It all starts with the manufacture of this mold, where a designer will carry out an analysis of the project’s needs and will create from there a mold of exact shape, with all the necessary specifications to have the greatest possible precision of details.

All stages of this process involve heating the raw material, injecting the mold, and cooling it. One by one the parts mold following the cycle of closing the mold, injecting the molten material, cooling, opening the mold, and removing the part.

Specialists in the project and product development

TIP-TOP Molds has experience in the plastic parts production market through injection molds. We are specialists in project and product development. In addition, we have software, and a team prepared to meet your demand with a high level of quality and finish.

Injection mold making company and prototyping

We have a high technological capacity to produce functional prototypes. This will give your project even more exclusivity and efficiency.

Injection mold manufacturing

We are strictly complying with deadlines and maintaining precision in the details. We have modern tools to develop plastic molds for the most varied segments.

All the novelties in the plastics market can find at TIP-TOP. As a result, our entire production relies on highly technological machinery.

The capacity of injection molding machines

With the capacity to process up to 2,000 tons of thermoplastics per month, the injection mold-making company has 30 injection molding machines from 60T to 2100T, injecting up to 20KG per injection. We meet and adapt our quality standards for large and small companies to suit your product type.

It is widely known that plastic injection molding can consistently produce thousands or even millions of plastic components. Products for consumer goods manufacturers, aftermarket parts suppliers, packaging companies, and automotive lines.

Injection mold making company complexity and composition

Plastic injection molds have the ability to produce a wide variety of products that vary in size, complexity, and composition. Applications for this highly repeatable and reliable process range from the simplest to the most complex parts.

How it works:

Once a part has been designed by a product engineer. The tool shop will create a mold, usually made of steel or aluminum. The mold can be a single cavity or multiple cavities, precisely machined to form the desired part.

Various polymers, including thermoplastics, thermosets, and elastomers, can be used in injection molds. Pellets of the chosen material heat in the gun of an injection molding machine. The mixture is flexible enough to inject into the mold.

In the injection mold-making company, a screw-type plunger forces the correct volume of material to fill the cavities under pressure. The two halves of the mold clamp tightly together. The material cools and solidifies in the cavity and is then removed from the mold by ejector pins.

Injection molding follows a four-stroke cycle.

First, the mold cavity fills with molten material, then the material quickly cools, causing it to harden (become solid). Then the mold cavity opens, exposing the part and giving it a space to exit, which happens when it finally pins out.

What is injection molding for?

There are several significant advantages to using an injection mold-making company. Here is a list of the most relevant:

Injection molding can be fully automated, allowing for very high production rates.

In conclusion, you can use a variety of materials in injection molds. Combine different materials to synthesize desirable material properties in your plastic product. The combination of more than one injection-molded material (usually two different materials) is known as co-injection molding.

There is typically very little waste during injection molding as excess material can easily repurpose.