Global plastic injection molding use has been increasing over the years. Most developers prefer it due to the lower costs of production compared to the other processes. Plastic has since replaced metal parts in different applications like aerospace, plumbing, and medical.
Lowering costs, however, is not enough. You must provide high-quality material with the right design, functions properly, and is durable.
Here are the tips to ensure the best quality plastic injection molding;
Select the right material
Material selection is one of the main factors when designing custom injection molding. The molding should match the prospective use environment.
The varying use cases involve surfaces with different chemical and mechanical properties.
For example, molding for high temperature and pressure engineerings like aerospace and automatic applications must withstand the high temperature while remaining dimensionally stable.
The best way to test the suitability of the material is to prepare on the temperature exceeding that of the expected usage environment.
Some of the thermoplastics ideal for intensive plastic injection molding are; Polypropylene for heat resistance and stiffness. Acrylonitrile butadiene styrene (ABS) is for a sturdy finish. It also allows for painting with glossy finishes.
Design for moldability
Designing injection molding is all about consistency and quality. An ideal mold should match the injection molding design and devoid of defects like sink, warp, and knit lines.
The major injection molding design applications are;
- Rounded features – avoid sharp corners and edges when designing the mold. This helps in resin flow, thus reduces stress while increasing strength to the parts.
- Wall thickness – consistent wall thickness helps controlling stress marks to avoid possible defects like flashing that can damage the mold. The thickness of the mold should correspond to that of the adjacent areas of unequal mass. The ideal mold is not less than 60 thicker to adjacent walls.
- Draft angles – the molding grip on the walls depends on the resin shrink and rate. Create a sound molding strategy to counter the grip on the draft angles. Modify the base to match the feature design. Reducing the parting lines rescues the possibility of mold flash hence lesser cosmetic effects on the molding.
- Ejection – treat the ejection molding as you would any other part of the project. Create enough space for pushing against a standard pin, or you might have to include stripper plates on smaller surfaces. Balance the application of the ejection molding on the surfaces with the thickness and mass in mind.
Pick the Right Manufacturing Partner
Working with the right manufacturing partner is the sure way to ensure suitable injection molding. Work with an experienced manufacturer who can handle the various materials for multiple surfaces.
The manufacturing partner should also provide enough lead time, affordable costs for the tooling and parts, and manageable minimum quantity requirements.
The more plastic injection molding becomes popular, the more they need for top quality. You need a mold that matches any environment it is applied.
Select the suitable material, design for moldability, and work with the right manufacturing partner for the best plastic injection molding.