Injection moulding machines are devices that assist businesses to create plenty of identical parts or products in a short time frame. Is your business about creating such types of products? Read on to learn more about these machines, how they work and if they are applicable to the brand.
What are injection moulding machines? How do they work?
Injection moulding is a process where users can mass-produce huge quantities of identical parts. By injecting molten material in moulds, a huge number (usually in the hundreds or thousands) of products can be created. Injection moulds are best used with thermoplastic polymers. However, moulds can even be created from other molten materials such as:
- Metals such as iron, aluminium, steel, etc.
- Silicon material
Factors to consider before buying an injection moulding machine
- Clamp tonnage
Clamp tonnage translates to clamping pressure. The term denotes how much pressure is applied while creating a mould. The machine presses the platens which hold the mould. The molten liquid is poured into the mould cavity after which the desired item is produced.
- Size of the Platen
Platen is the name that is given to the table which holds the mould in place. It is spaced apart from the mould. This is how it works:
- Once the molten liquid is placed in the mould, it gets clamped tightly to the plate.
- Once the platens are clamped securely, a couple of tonnage of pressure is applied to it.
- Then, the molten material is heated and injected with pressure.
- Once the desired shape has been given, it is given time to cool. This is called the moulding cooling cycle.
- The material assumes its final shape during the cooldown process. High pressure is still applied so that the item retains its shape after it is removed.
- Shot Size
The amount of the molten liquid injected through the machinery into the mould is called the shot size. The amounts are measured by different names. In the USA, it is measured by ounces. Elsewhere, it is measured by cm3.
Tip: When buying an injection moulding machine, consider buying a machine that can produce shot sizes at least 30% more than what the items actually require.
- Tie Bar Space
The holes between the moulds which allow the pins to pass through the platen are called Tie Bars. The space between the Tie Bars is called Tie Bar Space. The function of a Tie Bar Space is to determine the minimum and maximum sizes of the moulds that can be in the injection moulding machine at once.
- Ejector Stroke
The Ejector Stroke is a process in which the injection machine ejects the final mould with the help of ejector pins. This is how it works:
- The ejector is attached to the ejector plate on the mould.
- The ejector pins that are attached to the plate begin pushing the moulded part out after the cooldown process once the mould is opened.
- The ejector pins movements are synced with the mould opening movement to ensure minimal damage to the hardened product.
- Injection Volume
The maximum amount of mass the polymer belt can hold is called the injection volume. The maximum mass ranges from a minimum of ten to a maximum of a few thousand cm3 or pounds.
- Intercolumn distance
The specific distance between the injection moulding machine guides is referred to as the intercolumn distance. This sets the limitations of the minimum and maximum dimensions of the moulds that can be attached to the moulding machine. For example, the values could be 650*650 or 410*440mm.
Advantages of using injection moulding machines
- Improved efficiency leads to a quicker production
Using an injection moulding machine is one of the best ways to improve efficiency and hence, is also the most common method used. Here is why:
- Comparatively quicker than other mould creating methods.
- High production rate with a quick output.
- Quicker production leads to more savings since costs remain low.
- The speed may vary. However, a mould is created within 15 seconds to 2 minutes depending on its complexity.
Short mould creation cycles lead to massive production of mould parts in minimum time. This directly translates to increased revenue opportunities and higher profits.
- Complex designs of the parts
One of the biggest benefits of using injection moulding machines is that they can create very complex designs that even humans cannot make. What’s more, they are useful in making millions if not thousands of identical items.
Most experts agree there are elements without which the injecting moulding process works improperly. They are:
- The thickness of the mould’s wall
- The rib’s unique design
- Corner transitions
- Weld lines and gate placement
- Vent placement
- Improved strength
The strength to be applied is one of the biggest factors that the designer has to determine during the designing process. They need to evaluate if the moulded product has to be rigid or flexible. Accordingly, they adjust the gussets.
The key to efficient design is understanding how and where the customer will be using the created product.
- Minimal wastage
By using injection moulding machines to create spare parts, organizations can ensure a minimal amount of wastage by recycling all the excess waste generated. This is beneficial for organizations and can impact revenue and profits positively. How? Customers love businesses that make an effort to be eco-friendly and ethical through their CSR practices.
- Flexibility in terms of materials and colours
Another key advantage to keep in mind while designing a project for the injection moulding machine is choosing the right material and colour for the items. There are plenty of materials and colours available which makes the list of possible combinations endless.
With new technologies in the market, polymers have advanced too. This has enabled the development of newer resins as well for designers to choose from. A designer who is skilled in multiple types of resins will be able to give you the best quality products. These are a few things to keep in mind while choosing a resin:
- The elasticity of the resin
- Heat deflection
- Water absorption levels
- Tensile and impact strength.
- Reduced labour costs lead to higher savings
Injection moulding machines keeps human labour costs minimal since not many people are needed to monitor the machines. The machines are usually self-automated and have streamlined processes. Hence, they do not require much supervision. What’s more, the injection moulding machines have a very high output rate. This way, profits are maximised while human labour costs are minimal.
Haitian injection moulding machines are exquisite machinery that can suit almost all types of applications under different budgets. We find ways to work together to give your customers everything they require. Do contact us with your queries and we shall do our best to help you!