Thermoplastic injection molding

Thermoplastic injection molding

ST. construction of moulds for plastic materials, technical and sports articles. We specialise in the construction of mono-injection and bi-injection moulds in aluminium and steel for any type of plastic product. We have a workshop with 10 high quality workcentres with 3, 4 and 5 axes, and various CAD-CAM stations for designing mouldst. The largest tecnology for moulds plastic materials.

Moulds for plastic materials
Unique prototypes, perfectly finished, made with high quality materials for guaranteed long-life, with high-tech design solutions starting from the drawing or mathematical model of the final product supplied by the customer, SI.MEC’s technical office develops the mould project, in constant co-operation with the customer, offering the solutions most suitable for the specific characteristics: in this phase, the creativity and experience of the technicians integrate with the use of constantly evolving software.

ST group moulds- custom plastic injection molding service company in China
solutions for designing and making mouldsThanks to the on-going innovation of the software programs we use, we can pin-point the best solutions for designing and making moulds. Our technical office is always ready to adopt new solutions to satisfy the customer.

We are presenting some of our projects, achieved with renewed creativity, with the tiniest details taken care of, by controlling all process stages of the production of thermoplastic injection molding.

Plastic moulds parts
Unique prototypes, perfectly finished, made with high quality materials for guaranteed long-life.

A wide range of products and moulds for the plastic material industry like:

plastic mold partsElectroerosion for moulds for plastic material
Pallet changes
Mould adaptation
Polishing
Sandblasting and assembly
Plastic mould parts

the molding company
Injection moulds
Co-injection moulds
Manufacturer of plastic moulds
Plastic moulding

Plastic Molding Manufacturing
Injection mould
Moulds design
Moulds manufacturing

plastic molding company
Thermo plastic moulds
Moulds for plastic
Plastic materials for technical and sport articles
For further information about our products catalogue, please visit our official website: www.simec-moulds.com

Prototype And Mold Design

Prototype And Mold Design

Usually, the new designed products aren’t perfect, even can’t use. before make plastic mold the prototype is the first step to verify the feasibility, is the most effective way to find out the lacking, defects and drawbacks of the designed products. Prototyping usually is just making several samples, and the delivery is fast, cost is low, and more important is we can quickly find and improve the designed products, which provides a sufficient basis for stereotypes and mass production.
1, Test appearance design. Prototyping is not only visual, but also in touch, and you can reflects the designer’s creativity in kind intuitively, which can avoid the abuse of“Beautiful design but not beautiful products”.

2, Test the design structure. As the prototyping is assembly, so it can reflects the rationality of the structure and Installation of the products intuitively

3,  Avoid the risk of directly plastic injection mould making

4,  Make the product available much earlier. As the prototyping is in advance, you can prepare for publicize, earlier sale, produce the products use the prototyping before the mould making is finished, in order to dominate the market as soon as possible

What We Can Do?

Our company as a medium-sized factory for plastic products and Plastic injection mold design, mould making, plastic moulding and assembly, also is famous in china in prototyping factory. In the early stage of our factory, we are mainly focusing on rapid prototyping and mould making. Now, we can provide plastic prototyping, silicon prototyping and metal prototyping. According to the requirements of the customers, we are mainly use SLA/SLS and CNC prototyping.

Our Advantages:

1 Lower cost and higher quality than other places

2 Fast delivery as we equipped with advanced machines

3 Experienced as our operators are all have more than five years’ experience

4 Production methods are optional as we can provide two choice: SLA/SLS and CNC.

5 Material sundry, you can choose plastic prototyping( mainly use plastic), silicon prototyping(mainly use silicon) and metal prototyping ( mainly use Aluminum-magnesium alloy and other Metallic materials)

6 We can provide signal or several prototyping products

7 System management in all links.

Plastic Mold Design Service

Our company is equipped with professional designers, using of advanced design software and provide free design services for customers. Only tell us your idea, we can provide the perfect product design and mould design. As equipped with two professional plastic products and plastic mold designers, we can provide any products and injection mould design service according to the needs of customers. And we can convert design drawings into different file formats according to customer requirements to help customers to preview. Of course, as a serious company, we will strictly try our best to protect client’s intellectual property.

Our Advantages of Design Service:

1,  Low cost and even no cost sometimes

2,  Convenient Communication. All our designers are in good English skills, including speaking, writing and listening.
3,  Advanced skills with the advanced design software
4,  Experienced as all the designers are of over 5 years of design and practice experience
5,  Fast delivery as we have professional skills, advanced software, experienced and convenient communication which improves the efficiency and shortens the design time
6,  Many kinds of file formats, we can provide many kinds of file formats for the design drawing according the customers’ requirements.
7,  It is combination of theory and practice. When we design, we will comprehensive consideration of aesthetic and practical, economic and operational.
8,  Strictly Confidential. We will absolutely strict protection of customer data and intellectual property.
9,  Perfect Service. We provide not only design service, but also provide prototyping cost,plastic mold cost and Injection molding cost.
10,  Customer Satisfaction. We have clients worldwide, and if necessary, they can give you a reference.

Plastic Injection Mold Making And Laser Machining

Plastic Injection Mold Making And Laser Machining

The use of laser machining for making plastic injection mould has been available for years, but has only received limited acceptance. This is partly due to the uncertainty of the new technology and the cost of the machines.

However, for the right application, laser machining is a very viable option. With the latest generation of precision laser cutting machines, there are many improvements. Cutting speeds have increased, accuracy has improved, surface finishes are better, and the cost has come down.

How can laser machining help a plastic mold maker?

Precision laser cutting is an ideal operation for engraving and the machining of very intricate, small, shallow cavities. One of the benefits of laser machining is that it can engrave on complicated contours very consistently and with a high degree of accuracy. It is also possible to use laser machining services to engrave molds with changing vertical wall angles.

Laser micro machining can produce small, intricate and precise cores and cavities as well. Because the geometry is produced directly from the CAD file, the laser machining operation can faithfully reproduce the designed shape.

Are lasers accurate?

A precision laser cutting machine can cut within microns. The newer machines are also 5 axis and able to machine a wide range of angles and shapes. The XYZ positioning accuracy can easily rival that of a high quality CNC machining center.

Are laser engraving machines safe?

While it might sound dangerous, a precision laser cutting machine is actually quite safe. Of course, somebody might be tempted to ignore common sense and stare at the laser beam with their naked eye, but even this is not so easily done. Generally, however, the machine just hums away, doing its required task.

Are lasers fast enough to compete?

Depending on the application, a laser machining tool is financially justifiable. The applications are limited to shallow details, which eliminates many projects. However, if your need is for intricate, shallow details, precision laser machining could be the answer.

Because the entire process is computerized and automatic, it readily lends itself to small scale production. The engraving of logos is a great example. If your logo is to be cut into a contoured surface, it may not be possible to CNC machine it, or even EDM it. This is where laser machining can be a viable option.

Applications for laser machining

Small hole machining and shaped hole machining are good applications for laser machining. Turbine cooling holes are often laser machined. The helical shape of the blades are no problem for the laser because there is no tool holder to interfere. It is just a beam of light and the head is able to move about much easier than a milling machine, for example. go out other page to know more about plastic mold

EDM Supplies

EDM Supplies For WEDM And Sinker Electrical Discharge Machines

EDM supplies are often overlooked in the rush to get things done in a precision machine shop, tool-and-die shop or Plastic injection mold making shop. This wastes both time and money, yet the solution is quite simple.

Without the best EDM supplies, quality and production both suffer. Also, the workforce morale takes a beating because even the simplest of tasks becomes very time-consuming without the proper equipment and EDM tooling.

Typical WEDM supplies

  • Precision brass hole drilling tubes (hole popper tubes)
  • Filter cartridges
  • Resin-virgin and regenerated
  • WEDM tooling such as System 3R, Hirschmann, Erowa and Hermann Schmidt
  • EDM wires
  • Replacement parts
  • Rust inhibitors
  • Chillers
  • Metal polish
  • Cleaners
  • Magnets

 Typical Sinker EDM supplies

  • Graphite, copper and copper tungsten electrode material
  • EDM tooling such as System 3R, Hirschmann, Erowa and Hermann Schmidt
  • Tapping electrodes
  • Dielectric fluids
  • EDM filters
  • Chillers
  • Rotating spindles
  • Tubing chucks
  • Magnetic chucks
  • Pallets
  • Surface finish gauges
  • Inspection equipment
  • Microscopes

Take the time to find the best solution for each aspect of EDM

One shop owner I know invested heavily in a CNC sinker EDM, yet neglected to buy any additional tooling. He failed to see the wisdom in upgrading his accessories and thus rendered his new EDM to the status of a fancy manual machine.

Rather than add accessories piecemeal, include the necessary tooling in the initial package, or at least make a coherent plan to build up the tooling over time.

A very short history of EDM tooling

For the general public EDM is still a relatively unknown metalworking process. Unless one has personal experience or knows someone who works in this field, chances are quite good that the world of electrical discharge machining is a mystery.

Like any specialized industry, EDM has it’s own terminology and way of doing things. The slang that is used could easily mislead a bystander into thinking something quite different is going on than is actually the case.

Words like tweak, bump, tickle, feather, smack, toast, NFG, fudge, hide and zit are all used on a daily basis. Actually, zit is less common now than in the past, due to improved circuitry and techniques. A zit is a DC arc, or pit that is EDM’d into the steel by mistake.

With the ever-improving technologies available today, EDM has moved away from being somewhat of a black art and into a fully explainable and manageable metalworking process. No longer is it a machine of last resort or specialty, but a mainstay of the industry.

Robots, electrode changers and pallets for sinker EDM

At one time, not so long ago, electrodes were set up manually, requiring continual operator attention. There were no standardized holders and most people used angle blocks, vises or Vee-blocks to set up and hold electrodes. This actually worked quite well, but is very time-consuming and demands a high level of skill.

Next came the standardized electrode holders, such as System 3R. This changed everything almost overnight. Now electrodes could be moved from the milling machine, lathe or grinder and installed in the sinker EDM with no set up time.

Improvements were made on the holders and the repeatability and reliability increased dramatically. Pneumatic chucks made the process simpler and more accurate.

Tool changers were built into the sinker EDM to enable overnight machining and less operator involvement.

Now there are robots that select workpieces mounted on pallets and change electrodes, leaving the guesswork entirely out of the equation. These sophisticated tools require a high degree of organization, but once set up they can run almost indefinitely. Some tool magazines can hold 100’s of electrodes and many pallets with mounted workpieces.

Add pre-setting stations and inspection stations to the process and you truly have a complete manufacturing cell for the EDM department.

More articles on EDM manufacuturing of plastic molds please go to this website site.

Injection Molding Process

Injection Molding Process

The thought of processing PEEK (polyetheretherketone) or other high-temp resins can send nervous tremors through many a molder’s body.  I know, as a molder who learned the craft on a steady diet of PP and PE closures with their low melt temperatures and cold a plastic molds, my first PEEK experience made me edgy to say the least.  But I’ve since come to realize that PEEK is just another thermoplastic resin and, like the others, can be molded safely and efficiently with just a few precautions.

PEEK is widely believed to be one of the highest performing thermoplastics on the market and its end properties more than justify any trials and tribulations you may encounter processing it. PEEK is a linear aromatic, semi-crystalline thermoplastic having excellent wear, chemical and hydrolysis resistance. It has very low flame/smoke toxicity and excellent electrical properties that preclude the need for additives in many cases.

 

PEEK processes at a high melt temperature nearing 720°F, and both the press barrel and controls must be capable of this. On many plastic molding machines the high heat software is an option and I recommend ceramic high-temp heat bands whenever possible. A special screw and barrel are generally not needed, but consider hard units if running filled PEEK resins. We typically use sliding ring non-return valves, GP or Eliminator™ tips and don’t recommend ball checks or shutoff nozzles.

A hot mold is the key to achieving crystallinity in PEEK parts. Purging PEEK allows you to see the color change from a translucent to a solid colored crystalline state. If the mold is too “cold” (i.e. not hot enough) the parts will have that discoloration or partial translucency, and the quality of the end product will be compromised. The mold, in most cases, must be between 350°F and 450°F. This is steel temperature and requires oil or cartridge heat to maintain this level. Complex parts may require better temperature control so oil would be the preferred option. We also recommend the use of thermocouples to verify and monitor the steel temperature.Plastic Mould & Plastic Molds

These plastic molds must be specifically designed to run high-temp materials with draft, finish, undercuts and steel types all factored in from the beginning. Insulator plates between press platen and mold clamp plates are a must. The preferred steel type would depend on whether or not the resin uses any abrasive fillers but should have a minimum hardness of 52-54 Rc.

The resin also must be very dry to process well and achieve the desired end properties. This means that the resin must be at 0.02% moisture or below. We typically recommend drying the resin at 300°F for at least 3 hours. We also suggest the use of a moisture analyzer to assure dryness.

PEEK can be quite costly, but you should be able to use 30% dry first-pass regrind with unfilled PEEK and 10% with filled PEEK.

Safety should be a primary consideration when molding PEEK, both for purging and while working with the mold. Wear safety glasses and/or a face shield, Kevlar or Kevlar/stainless steel sleeves, and heavy cotton cloves when purging and reaching into the mold.

When preparing for your PEEK experience, research it well with your resin supplier. The above information is based on my experience, but it should used as a reference only. Also, make sure you don’t neglect recognized scientific principles when working with any thermoplastic material. With a bit of common molding sense, your PEEK experience can and should be a rewarding one. click here to get more detail about plastic molds and plastic molding technology.

Injection Molds

Injection Molds

The world has become very dependent upon plastic products. From household items to industry and aerospace, plastic in its many formulations has transformed modern manufacturing and created conveniences and economies unimagined in the early decades of the 20th century.

Injection Molds
The injection moulding industry took hold in 1946 when James Hendry built a screw injection molding machine. But, his technology was based on an earlier invention by John Wesley Hyatt who, in 1868 injected hot celluloid into a mold to make billiard balls. Hyatt’s method used a plunger to force the ma

terial inside a mold. Hendry’s improvement was revolutionary because it eliminated the plunger and replaced it with an auger-type action that better distributed material and facilitated the use of plastic inside molds.

 

Today’s plastic molds use much the same process and produce a wide variety of products from car panels to outdoor furniture, small toys and tools. Injection molding is ubiquitous in manufacturing and uses many different materials from polymer plastics to aluminum, copper and other metals. The plastic bottles and kitchen implements people use in everyday life are products of the injection process.

Because the metal molds are generally expensive to produce, Plastic molding is most economically used when thousands of pieces are being manufactured. Molds are made of hardened steel or, more recently, aluminum which is less expensive.

The Injection Process
Described very simply, molten plastic is injected into the mold under high heat and pressure. The goal is to have the molten plastic material evenly flow to all parts of the mold, creating an exact, consistent, solid plastic replica of the mold cavity. After a brief cooling cycle, the mold or tooling mechanically ejects the plastic part which then moves on through the manufacturing process. In the injection molding industry, this is a completely automated process that’s very fast and extremely efficient.

Rotational Molding
Rotational molding is yet another method of producing multiple products, most often made with a variety of plastic powders. This process is usually used in making hollow products such as traffic cones, canoes, kayaks, bicycle helmets and giant tanks used for water or chemical storage.

Like Injection molding, rotational molding had its roots in the 1940s. But it was not until the technology was more sophisticated and new polymer and plastic formulations became available that the rotational process became a mainstream manufacturing method.

Rotational Process
The two processes are quite different. Let’s consider, for example, a 300 gallon water storage tank made of polyethylene. Picture a master mold made of aluminum or steel. The plastics manufacturer pours poly resin powder into the mold that is fitted inside an oven. Once sealed, the mold is mechanically turned on at least three axes, moving much like a gyroscope. At the same time, the oven is raised to an appropriate temperature and the polymer – or other material – tumbles inside and slowly coats the inner walls of the mold, melting as it rotates.

Once the optimal temperature is reached, the mold is cooled. As the temperature of the mold itself falls, the product on the inside shrinks away from the inner walls and is easily removed. This is not always the case with injection molds that are often more difficult to successfully remove. The shrinking action of rotational molding is particularly desirable when the product is very large and awkward to handle.

Rotational molding is also more economical for some products because less material is used. In addition, the polymer that is left over from one mold can be used in another. The method itself is more streamlined than injection molding, which requires more interlocking parts.

Materials Improve and Expand
Most products made with the rotational molding method are from the polyethylene family. Other materials include nylons, polypropylene and PVC plastics. Some manufacturers have developed formulas that integrate the use of natural materials such as sand and chips of stone to make products.

Plastic and resin products are now an integral part of everyday life and supply us with items as tiny as paper clips and as big as storage tanks. As the industry developed, so too has environmental awareness about the safety and use of these petrochemical-based products. Today, materials can meet the specifications of FDA requirements, and other health and safety related regulations. Producers are also cooperating to create products that can be recycled.

Injection Molding Machines

Injection Molding Machines

The injection molding process was invented in 1872. Since then, the injection molding business and the plastic industry has ballooned into a multi billion dollar business venture. In fact, thirty two percent of plastics by weight are processed through injection molding. Injection molding has greatly helped in making the US economy boom because through it, cheap and durable consumer and industrial items essential to almost all industries is made possible.

Components of the injection molding machine

The injection molding machine converts granular or pelleted raw plastic into final molded parts through the use of a melt, inject, pack and cool cycle for thermoplastics.

A basic injection molding machine is typically composed of the following: injection system, hydraulic system, mold system, clamping system and control system.  The clamping tonnage and shot size are both used in identifying the dimensions of the injection molding machine for thermoplastics, which is the main factor in the whole process. Other consideration include rate of injection, pressure, design of screw, thickness of the mold and distance between tie bars.

Plastic Injection mold & Injection molding

Functions of the machine

The injection molding machine can be classified into three categories, namely: general purpose machines, precision/tight-tolerance machines and high-speed thin-wall machines. All three types require auxiliary equipment to function.  These support equipment includes dryers (resin), material handling equipment, granulators, mold temperature controllers and chillers, part-handling equipment and part-removal robots.

There are a lot of companies specializing in quality plastic molding, but they are not all the same. The best ones fast, flexible and customer driven both for large and small quantities. These companies usually have state-of-the-art facility with full scale thermoplastic and thermoset capabilities, computer-aided manufacturing, skilled machine operators and quality assurance team. Injection Molding provides detailed information on Injection Molding, Plastic Injection Molding, Injection Molding Machines, Custom Injection Molding and more.

Plastic Mold

Plastic Mold

Plastic has, quite literally, become the cornerstone of our society.  We make so many things from plastic that it is hard to imagine what our lives would be like if it was never invented.  With so many of our everyday products being made of plastic, it is easy to understand why plastic injection molding is such a huge industry.

Approximately 30% of all plastic products are produced using an injection molding process.  Of this 30%, a large amount of these products are produced by using custom Plastic Mold technology & injection molding technology.  Six steps are involved in the injection molding process, after the prototype has been made and approved.

Plastic Mold

The first step to the injection molding process is the clamping of the injection mould.  This clamping unit is one of three standard parts of the injection machine.  They are the mold, the clamping unit and the injection unit.  The clamp is what actually holds the mold while the melted plastic is being injected, the mold is held under pressure while the injected plastic is cooling.

Next is the actual injection of the melted plastic.  The plastic usually begins this process as pellets that are put into a large hopper.  The pellets are then fed to a cylinder; here they are heated until they become molten plastic that is easily forced into the mold.  The plastic stays in the plasatic mold, where it is being clamped under pressure until it cools.

The next couple of steps consist of the dwelling phase, which is basically making sure that all of the cavities of the mold are filled with the melted plastic.  After the dwelling phase, the cooling process begins and continues until the plastic becomes solid inside the form.  Finally, the mold is opened and the newly formed plastic part is ejected from its mold.  The part is cleaned of any extra plastic from the mold.

As with any process, there are advantages and disadvantages associated with plastic injection molding.  The advantages outweigh the disadvantages for most companies; they include being able to keep up high levels of production, being able to replicate a high tolerance level in the products being produced, and lower costs for labor as the bulk of the work is done by machine.  Plastic injection molding also has the added benefit of lower scrap costs because the mold is so precisely made.Plastic Mould

However, the disadvantages can be a deal breaker for smaller companies that would like to utilize plastic injection molding as a way to produce parts.  These disadvantages are, that they equipment needed is expensive, therefore, increasing operating costs.

Thankfully, for these smaller companies, there are businesses that specialize in custom plastic injection molding.  They will make a mock up mold to the exact specifications, run it through the complete process and present the completed piece along with an estimate to complete the job to the customer.

Linda Moore writes on a variety of subjects including home ownership, travel, personal enrichment,

Injection Molding

Non stick coatings for injection molding Parts?

Yes! Just recognize the difference between ‘lubrication’ and ‘release’ and you need never fail again.

Today, there are a number of hard coatings for you, the mold maker, to choose. Many are conformal in nature and replicate surface geometry and finish. Many, too, resist thermal oxidation and can wear well. But what about release? You know, actual non-stick properties, like an egg cooked in a fry pan?

The answer for injection molding is not lubrication. And here is why.

Lubrication is defined as a means to reduce friction or wear. That is true. But it is meant to be a substance between two bodies in relative motion, a load bearing interface between two solid, cohesive surfaces. And that is not what you find when you heat the mold surface above your material glass transition temperature (Tg). Which is why hard coatings designed exclusively for lubrication fail.

Depending on the compounds you are molding, ‘sticking’ failures can manifest in a number of ways: skinning, loss of polymer mobility, lower gloss and surface roughness. Hard coatings ‘with lubrication’ can negatively affect heating and cooling which, alone, can alter depth and visibility of weld lines.

On the other hand, hard coatings for non stick can make significant improvements to finish. Surface flaws can be eliminated. And that means no more painting. Structural imperfections, too, like molded in stresses, which lead to warping or distortion, can be a thing of the past.

Unfortunately, Plastic mold makers who have had negative coating experiences are reluctant to re-consider. No different than those currently experiencing satisfactory but marginal performance. Why change, they say. Especially when you believe you have tried or know about all the coatings available, today, like plating, Teflon or PTFE, PVD or PACVD.

So, where is your answer? Just ask around. You will not have to look far. The answer, you will discover, is with those who understand surface forces, the characterization of adhesion, non stick coatings for injection molding parts.

Want more information? Need help with your surface engineering?

William Gunnar, a degreed scientist, researcher, engineer, and friend, has helped thousands of ‘best of class’ product designers and equipment manufacturers — for nearly 20 years now — surface engineer with coatings for success.

His publication, brings wisdom, honesty, leading edge information, and no nonsense advice to thousands weekly. Put together by some of the world’s leading experts in coatings and manufacturing, his FREE newsletters are truly must-reads for those who want to be ‘in-the-know’.

Custom Injection Molding

Custom Injection Molding

If  your business needs plastic molding products with specific types and dimensions, then you should turn to custom injection molding companies. These manufacturers have the ability to make plastic parts for specific applications – they can customize virtually all plastic components per your requirements. They can stamp your logo or messages, produce unique colors and designs and package them specifically based on what you want and need.

Choosing a custom injection molding company

Most of the custom injection molding companies can produce any plastic product you specify, but not all of them go the extra mile to take care of ‘finishing services’ such as decorating, assembly, labeling and packaging. Some even have a design group that can assist clients with plastic part and mold design. From rapid prototyping and tooling to injection molding, ultrasonic and plastic welding and stamping, these companies can assist you every step of the way. Go for manufacturers that offer these added perks – you will end up saving time, money and effort.

Note that some custom injection molding companies do not do these extras in-house – they hire sub-assemblers and finishers, but are still able to produce products at par with your standards.

Also examine the manufacturing company’s logistics and scheduling system. They should be able to handle your delivery needs no matter how demanding they may be. You should also go for companies that implement strict controls to monitor the whole custom injection molding process. They should have the latest inspection equipment at hand to allow them to match the closest tolerance and thus provide quality consistently.

The custom injection molding company’s plant climate is also very important. They should have facilities that ensure mold cooling system control. You may contact any companies in the internet directory for your custom injection molding needs. injection Molding provides detailed information on Plastic Molds, Injection Molding, Plastic Injection Molding, Injection Molding Machines, Custom Injection Molding and more.