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How To Buy High Quality Plastic Injection Mold

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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

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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

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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

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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 Molds

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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.

Plastic Mold

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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 plastic 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

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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

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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.

What Is Plastic Molding

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What Is Plastic Molding

Plastics are synthetically produced non-metallic compounds. It can be molded into various forms and hardened for commercial use. Plastic molding products can be seen everywhere. Examples are jars, protective caps, plastic tubes, grips, toys, bottles, cases, accessories, kitchen utensils and a lot more.

Even the keyboard and the mouse that you use are made through plastic molding. Even the plastic parts of the chair that you are sitting on are created this way.

The basic idea in plastic molding is inserting molten liquid plastic into a ready shaped mold, for example the mold of a bottle. It will be then allowed to cool, then the mold will be removed to reveal the plastic bottle.

Plastic moulding can also custom-mold a wide variety of plastic products including: garden pots, cabinets, office trays and boxes, barriers, barricades and traffic signage and displays for product and marketing promotions.

If you are planning to go into plastic molding business, you should first know the different processes.  Choose from a plastic molding process that fits your budget, your expertise, and your resources. Here are basic definitions of various methods of plastic molding.

The Plastic Molding Processes:

1.      Injection Molding

In Injection Molding, melted plastic is forced into a mold cavity. Once cooled, the mold can be removed. This plastic molding process is commonly used in mass-production or prototyping of a product. Injection molding machines were made in the 1930’s. These can be used to mass produce toys, kitchen utensils, bottle caps, and cell phone stands to name a few.

2.      Blow Molding

Blow molding is like injection molding except that hot liquid plastic pours out of a barrel vertically in a molten tube. The mold closes on it and forces it outward to conform to the inside shape of the mold. When it is cooled, the hollow part is formed. Examples of blow molding products are bottles, tubes and containers.

Equipments needed in setting-up a blow molding business are relatively higher than injection molding.

3.      Compression Molding

In this type of plastic molds, a slug of hard plastic is pressed between two heated mold halves. Compression molding usually uses vertical presses instead of the horizontal presses used for injection and blow molding. The parts formed are then air-cooled. Prices of equipment used for compression molding are moderate.

4.      Film Insert Molding

This plastic molding technique imbeds an image beneath the surface of a molded part. A material like film or fabric is inserted into a mold. Plastic is then injected.

5.      Gas Assist Molding

Also called gas injection molding is used to create plastic parts with hollow interiors. Partial shot of plastic is then followed by high-pressure gas to fill the mold cavity with plastic.

6.      Rotational Molding

Hollow molds packed with powdered plastic are secured to pipe-like spokes that extend from a central hub. The molds rotate on separate axes at once. The hub swings the whole mold to a closed furnace room causing the powder to melt and stick to the insides of the tools. As the molds turn slowly, the tools move into a cooling room. Here, sprayed water causes the plastic to harden into a hollow part. In this type of plastic molds tooling costs are low and piece prices are high. Cycle time takes about 40-45 minutes.

7.      Structural Foam Molding

Structural foam molding is a process of plastic molding usually used for parts that require thicker walls than standard injection molding. Inserting a small amount of nitrogen or chemical blow agent into the plastic material makes the walls thicker. Foaming happens as the melted plastic material enters the mold cavity. A thin plastic skin forms and solidifies in the mold wall. This type of plastic molding can be used with any thermoplastic that can be injection molded.

8.      Thermoforming

In this plastic molding process, sheets of pre-extruded rigid plastics are horizontally heated and sucked down into hollow one-piece tools. When the hot plastic solidifies, its shape conforms to that of the mold.

Tooling costs are usually low and piece prices vary on the machinery.

Plastic molding is a very technical process. It needs experts in this type of manufacturing business for it to be competitive in the market. Therefore, a very scientific and systematic study should be first made before going into this endeavor, if you want to know more about us, please go to our mean website to know more.