How To Buy High Quality Plastic Injection Mold

How To Buy High Quality Plastic Injection Mold

There are plenty of injection Mold Company in China, especially gathered in Guangdong province and Zhejiang province. Then how to customize good quality plastic injection mold? How to choose most suitable mold company?

Mold flow analysis

Before detail mold design, should have mold flow analysis of plastic part. By analyzing material flow direction and path route, check whether injection gate reasonable or not, or there is any flowing imbalance or other problems.

Professional Plastic mold design

Mold design is the basic, also it is the first important item for mold manufacturing. It must be reasonable, based on exact plastic part’s requirement, then to have the most appropriate design. For example, PVC injection molding, if plastic part small, better to use valve gate system or submarine gate. For large PVC part with thick wall, then better to use fan-shaped gate type.

 

Mold tooling

Good quality injection mold related to precision mold tooling. For example, medical syringe barrel mold, it has strictly requirement of mold core part’s verticality, almost there is no demolding angle, as require sealing the best between barrel and gasket. Here best to use Japanese brand Sodick precision wire cutting machine, mold dimension can be controlled within 0.005mm. Additional, Fidia three axis high speed CNC machine from Italy, Agie Charmilles EDM machine from Switzerland, are most suitable for tooling high precision plastic mold for medical plastic parts, packaging parts and automotive parts. When you hesitate to choose which mold company, to check their tooling equipments first.

 

Mold installation

After all above items smooth finished, then comes to labor works. Mold assembling and installation should be done carefully, workers should pay attention to this part, make sure every spare part has been assembled and in most suited location without any damage. Also make sure under safety condition.

 

Mold adjusting and testing

If injection mold have any problem, then it can be directly reflected on plastic parts. Mold testing is important, as custom plastic mold company and client will have fully understand, then know how to fix the mold or next. So at first, all related auxiliary equipments should be well installed, like air blow system, water cooling system, etc. Check its reliability, then add plastic material to test the mold. At the same time, injection molding condition should be suitable.

 

Mold maintenance

Suitable maintenance of injection mold is important. This will prolong mold life time, also you may have the idea of this injection molds company, how their attitude of the mold manufacturing.

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 Molding In China

Plastic Injection Molding In China

Plastic injection molding in China is at a high level of expertise in comparison with other Asian countries. Taiwan also has much better working conditions, environmental regulations and worker relations than most it’s neighbors.
Government policies that have enabled the plastics industry to develop in a free-market manner. This has enabled the plastic injection molding industry to develop to a high technical level. The open market nature has given fair competition the ability to bring in high end jobs and industries.

What are some advantages of China injection molding manufacturers?

  • Decades of industrial growth and stability without destroying the environment
  • Safe and healthy working conditions for the employees. Taiwan has a long history or good human rights relations which reflects in it’s labor laws.
  • For the environment. Industry has cooperated with the government to keep the island clean and relatively unpolluted
  • Costs are generally one-third less than those of the USA. This means you can receive high quality at reduced prices.
  • Thermoplastic injection molds, thermosetting molds, and custom molds of all types have developed to a high level of expertise.
  • No history of human rights abuse

What are some industries China specializes in?

China has an excellent relationship with the US, Europe and Japan because of it’s political and economic system. This has enabled the island country to attract leading aerospace, automotive, electronics, computer, and small appliance companies.
How can you find a reliable plastic injection molding company in China? A good place to begin your search is here One of the top companies in Taiwan for thermoset molding is Longzu Plastic Molding Company They have been in business for over 40 years, which is a lifetime in plastics.

How to make plastic injection mold

How to make plastic injection mold

The process of making a plastic injection mould consist of determining what should be the size of
the mold, designing the mold, ordering required materials for the design, creating a rough shape, heating the mold, precision machining, wire cutting, polishing and fitting and trial of the mold.

Step 1: Determining the size of the plastic injection mold.

This process is not hard and does not require a lot of time. The end product, the plastic shape, determines the size of the mold.

Step2: Designing the mold.

Computer CAD design is used to draw the design. First set a 2 dimension layout and make sure you have all the mold
design features marked such as the size of the mold, parting line, the layout of the cavities are all set. Note the information that will be needed such as the mechanical design and the accessories that will be used.

After the two dimension layout made is satisfying and all information is noted make a
detailed 3D design. This will require programming skills to create. It may take some time to complete the designing with regards to the complexity of the mold.After the first 3D design is made it is necessary to assess any need for adjustments and the flow of the mold.

 

Step 3: Ordering the required molding material

After your design drawing is completed its time to order the required material. This may include desire steel, cutting tools and plastic part samples.

Step 4: Creating a rough shape of the plastic molds

Sizing of the steel then milling and drilling comprises this step. Make the desired steel shape and drill the holes needed as per the design in a rough work machine. Leave polishing and smoothing for later.

Step 5: Heating the mold

Heating is done as a form of treatment after creating the rough shape to harden and balance the created steel shape. Not every type of steel may need heating, an example, the P20.

Step 6: Precision machining.

Precision machining works slower due to the hardened steel properties but will get the design dimension created as per the design drawing.

Step 7: Wire cutting and EDM

Wire cutting is a process where special holes are made in to the design. These holes include pin holes for the ejector, for the lifters and the inserters. EDM helps work on narrow spaces which cannot be machined easily or where the space is too small for the cutting tool to get in.

Step 8: Polishing and fitting
polishing and fitting the created mold in to the mold maker machine follows.
The mold maker machine will collect all parts put into it and will follow the
design drawing to make the finished plastic mold. When the machine work is done further
polishing and engraving follows to complete the design.

Step 9: Trying the mold.

After the mold is created it will be good to try if it will work for the desired plastic shapes. The mode is installed in the plastic injection molding machine and injection parameters are set to work on the plastic samples acquired. If the mold is good enough for the job, well and good, the mold creation process is complete. You can now proceed to create the desired plastic products or sell the design to another company.

 

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.