Posts Tagged ‘plastic injection mold maker’

Reasons Why Automation is Vital for Injection Molding Today

Reasons Why Automation is Vital for Injection Molding Today

Automation in Injection MoldingAutomation in injection molding projects minimizes hands on involvement, resulting in improved consistency, repeatability, product quality and ultimately the best value for the customer.

Robotics can be used throughout the injection molding process during the insert molding or over molding process, helping to assist in secondary operations and quality inspections.  Using automation processes can eliminate waste, produce consistent quality components and at a faster cycle time.

Reducing the need for manual intervention in the molding process

To make the insert molding and over molding process more efficient, robotics are often utilized.  Injection molders make use of robotics to place the metal components in a molding machine before the insert molding process and then perform secondary operations like part trimming and packaging.

Injection molders can take advantage of the use of robots in the over molding process by removing a molded part or substrate from one injection molding machine and then placing it into another injection molding machine for the over molding process.

Using robotics to complete as many tasks as possible frees up time and resources for any required hands-on processes. It also makes it possible to repeat those tasks over many cycles with consistency and predictability.

Robots are also used for secondary operations in the injection molding process.  Some samples of use of robotics in secondary operations are for part trimming, drilling or clipping.  As well as in assembly of injection molded components either by welding, bonding or adhesives. Automation is also used for sorting of product for further processing and packaging components to be shipped to customers.

Precision and consistency in plastic injection molding are important quality considerations. Without having both, you cannot produce high quality injection molded parts.

Measuring quality specifications using fully programmable, automatic CNC-driven quality inspection and measuring equipment to verify critical dimensions on first article inspections and production samples or runs enables accurate and reliable data every time. This takes the human element out of the equation and enables timely corrections in the production process.

Guidelines For Avoiding Costly Mistakes Plastic Parts

Guidelines For Avoiding Costly Mistakes Plastic Parts

Errors, that newcomers regularly make whilst beginning to design plastic parts can often be discovered by Rapid prototype parts before commencing to construct an injection mold. I am going to point out some frequently made mistakes and present several suggestions for designing the perfect plastic parts.

The procedure of producing plastic parts differs from making other components like metal parts. An important practice in designing plastic components is to attempt to sustain identical wall thickness. Parts with uneven wall thickness are likely to cool irregularly and leave bad shrink marks which are noticeable on the outer surface. In addition, this might bring about tension at the junction of high and low shrinkage and cause the part to warp.

Given that plastic components are shaped by injection molding, they must be designed with a draft. Draft is the angle of taper of a wall. A draft angle of 0.5 degrees is considered as a bare minimum for many appliances. Draft angles of 1.5 to 2 degrees are regarded normal for plastic injection molding.

Whilst using a thin wall thickness, every so often it is required to increase the stiffness of a component. One frequently used technique is to include ribs. Yet, when adding ribs a few guidelines have to be adhered to. The thickness of the rib ought to be smaller than the wall thickness. Typically ribs are 60% to 80% of the wall thickness and spaced no less than 2 times the wall thickness apart. Don’t make the height of the rib upwards of 3 times the wall thickness. It is better to increase the quantity of ribs as opposed to the rib height.

Bosses are utilized as components need to be mounted and are now and then designed with thick wall sections that may affect the look of the final parts.  As a guideline , the wall thickness around a boss should be 60% of the nominal part thickness if that thickness is smaller than 1/8 inches. If the part thickness is more than 1/8 inches, the nominal part thickness ought to be 40% of the wall thickness. In order to avoid sink marks and voids, the next rule should be observed when determining the height of the boss. Ideally the maximum height of the boss ought to be no more than 2.5 times the boss hole diameter.

When designing plastic components, sharp corners should be avoided. Sharp corners can lessen part strength and act as stress risers. Sharp corners moreover effect plastic flow causing parts with nasty surface patterns. The internal radius of bosses and ribs should be one quarter of the part thickness, yet a minimum of 0.015. The inside radius of other corners ought to be a minimum of half the wall thickness. The exterior radius should be the internal radius plus the part thickness.

Guidelines For Avoiding Costly Mistakes Injection Molded Plastic Parts

Guidelines For Avoiding Costly Mistakes Injection Molded Plastic Parts

Mistakes, which newcomers regularly make whilst beginning to design plastic components can regularly be discovered via Rapid prototype parts before starting to construct an injection mold. I will point out a number of usually made mistakes and present some pointers for designing the perfect plastic components.

The method of manufacturing plastic components is different from producing other components such as metal components. An important practice in designing plastic components is to try to maintain identical wall thickness. Parts with irregular wall thickness are likely to cool unevenly and leave nasty shrink marks that are visible on the outside. In addition, this might cause stress at the junction of high and low shrinkage and cause the part to warp.

Given that plastic components are shaped by injection molding, they ought to be designed with a draft. Draft is the angle of taper of a wall. A draft angle of 0.5 degrees is considered as a bare minimum for a lot of appliances. Draft angles of 1.5 to 2 degrees are regarded customary for plastic injection molding.

Whilst using a thin wall thickness, now and then it is crucial to raise the rigidity of a part. One usually used technique is to add ribs. While inserting ribs, be sure to make the thickness of the ribs less than the thickness of the wall. Normally, ribs have 60% to 80% of the wall thickness. When multiple ribs are utilized, they must be spaced at the least 2 times the wall thickness apart. It is best to keep the height of the ribs less than 3 times the wall thickness and rather add more ribs instead of increasing the height of the ribs.

Bosses are another design building block used for mounting and assembly purposes. Regularly, bosses are designed with thick wall sections that can influence the appearance of the plastic component and the finished product.  As a guideline , the wall thickness around a boss ought to be 60% of the nominal part thickness if that thickness is smaller than 1/8 inches. If the part thickness is more than 1/8 inches, the nominal part thickness ought to be 40% of the wall thickness. In order to avoid sink marks and voids, the next rule ought to be adhered to while determining the height of the boss. Ideally the greatest height of the boss should be no more than 2.5 times the boss hole diameter.

When designing plastic components, sharp corners ought to be avoided. Sharp corners can lessen part strength and act as stress risers. Sharp corners moreover effect plastic flow producing parts with unappealing surface patterns. The inside radius of bosses and ribs ought to be one quarter of the part thickness, but a minimum of 0.015. The internal radius of other corners should be at the least half the wall thickness. The outer radius should be the inside radius added to the part thickness.