Injection molding is a process of manufacturing parts by injecting material into a closed mold. Injection molding can be performed with a wide variety of materials, including metals, glass and, in some cases, elastomers and thermoset polymers. The parts to be molded by injection must be carefully designed to facilitate the molding process.
The material used for the part, the shape and the desired characteristics of the part, the material and the design of the mold, as well as the properties of the molding machine, must be taken into account. It is essential to consider the number of parts required and the useful life of the tools. This is because injection tools and presses are more complex and, therefore, more expensive to install and use than other molding techniques. Therefore, small batches of parts may not be profitable if manufactured by injection molding.
Most plastic products are manufactured by injection molding. This process is attractive to manufacturers because of the many advantages offered by other plastic molding methods.
In general, injection molding is simpler, more reliable, more versatile and more efficient than most other types of injection molding.
Plastic injection molding operates at a very high pressure, which means that melted plastic is pressed harder against the mold than in other molding processes. This provides the advantage of a greater amount of detail in the design of the piece being molded, includes complex geometry or detailed features.
The molding process is also very fast compared to other molding processes. A complete molding process takes very little time, which allows much more products to be generated by the same mold. Therefore, you will get much more mileage in a single mold. Injection molding is highly efficient.
Injection molding is a highly automated process. Most injection molding is done by machines that can be executed by only one operator. Therefore, very little up will have to go to pay the labor force in a plastic injection molding process.
Injection molding is a monomer-free process. Monomers are a type of plastic that generate a lot of smoke, which many people have a negative physical reaction. Therefore, any molding process that employs monomers requires a good amount of ventilation. If you use injection molding, you will not have to worry about these problems.
When using injection molding, you have the option of molding two different types of plastic at the same time. This process is called coinjection molding. Therefore, you do not have to worry about access to a certain type of plastic.
Die casting makes the use of thermoplastics. Thermoplastic can be injected into the mold; then the excess can be re-melted and used again. Therefore, injection molding can save on materials. Thermoplastic can also come in a wide variety of densities or strengths.
Plastic injection mold offers you the option of using fillings in your molds. Fillers are used to reduce the density of the plastic as it is molded as well as provide greater resistance to the product once it is molded. This is another method of reducing the total cost of the process.