Do you need a product mass-produced as soon as possible? Are you new in this industry and wondering what the best and most efficient plastic manufacturing method for your needs is? If you are here, maybe heavily considering going plastic injection molding.
This article aims to share everything you need to know about plastic injection molding and why it is the best option for your plastic manufacturing needs. We will also be providing you some tips on how you could find the best plastic injecting molding experts and services.
Common Types of Plastic Manufacturing Processes
To start, you should have an idea of what other options you may consider with plastic production. Here are some common types of plastic manufacturing processes:
CNC Machining
Control Numerical Control or CNC Machining is a type of manufacturing process where everything is controlled and monitored by a computer program. Instructions on how the product will be produced from the material are pre-programmed using codes or CNC programming languages. The most common products made with CNC machining are firearms, pens, instruments, etc.
Plastic Extrusion
The extrusion process starts with the melting of plastic beads or resins. The machine will then process the polymer to create the final product, usually extruded objects in a continuous profile like gutters, pipes, etc. The main difference between extrusion and injection molding is that the former produces two-dimensional products while the latter creates three-dimensional ones. PVC is a common extruded plastic.
3D Printing
3D printing is another modern way of manufacturing plastic products. Like CNC machining, 3D printing is entirely controlled by a coded instruction program. Unlike with extrusion, where the polymer has to be forced through a die, with 3D printing, the melted plastic comes out of a nozzle. Every movement of the nozzle is based on the program. Nowadays, you can create anything with a 3D printer.
Polymer Casting
Unlike the processes mentioned above, which are entirely done by giant machines, polymer casting requires more manual labor. The resin is poured into the desired product’s flexible rubber mold, solidifying after some time. Once the resin has hardened, the product can be removed from the mold. And with a few touch-ups, the item is ready.
What is Injection Molding, and why is it better?
Plastic injection molding is considered to be the best manufacturing method for the mass-production of parts or any plastic products. As we mentioned earlier, three-dimensional products can be done with injection molding. Large injection mold machines are being used for this process.
There are four general steps in plastic injection molding: clamping, injection, cooling, and ejection. However, before all of that, the mold to be used for the product must be designed and produced.
The entire process starts with clamping, where the two halves of the mold are clamped or fastened on the machine. The machine has to make sure that both halves are closely pressed to each other while injection begins.
With the injection process, plastic pellets are poured into the machine and proceed to the injection unit, where the high heat melts them. The melted pellets will then be forced onto the mold to take their shape.
Once the molten plastic is in the mold, the mixture starts the cooling process. This is the part where the plastic begins to solidify and stay in the shape of the mold. The cooling time, which may take a while depending on the product, must be entirely finished before it proceeds to the final step.
Lastly is the ejection. With force, the machine has to eject the part from the mold, making sure that it loosens the adherence. And the product will just fall from the mold. From there, the process will just repeat itself where the clamps have to push the two halves of the mold close together.
Plastic injection molding is best in producing plastic parts that have to be mass-produced, like car parts, medical instruments, bottle caps, mobile cases, etc.
Things to Consider with Plastic Injection Molding
If you are set on going with plastic injection molding, it is vital for you to know all factors to consider before you start engaging with a manufacturing company. Here are the considerations you have to keep in mind before the process.
1. Your budget
Initial costs for injection molding can be pretty high because the machine has to be set up correctly. You also have to invest in a good-quality production of mold. Several testing and prototyping also have to be done to ensure that everything is up to standard before mass-producing or the injection molding proper.
2. The quantities of products to be produced
Determine and finalize beforehand how many parts you want to produce. Keep in mind that with plastic injection molding, it is more cost-efficient to produce quantities of products that, once sold, will help you breakeven with what you already invested for the other aspects of production, like testing, designing, etc.
3. Mold design and tooling
Design the product or part, the mold, and the mold tools in a way that is most efficient for injection molding. It will help you avoid any defects or problems along the path of production.
4. Production timeline
Prepare a timeline that covers the production from molding to assembly. It will help you monitor progress, ensure that things are getting done and that the production will finish on time.
5. Issues that may arise during production
It is vital to have good foresight when it comes to businesses like this. You have to know possible issues that you may encounter during the production. Think as if you are anticipating these problems and, from there, create backup plans that can help smooth them out without any conflicts in case they arise.
6. Injection molding experts you will be working with
Lastly, and most importantly, seek an injection molding company that suits your needs. They are the ones who will carry this project out, so you should hire those who are the best in the field. You should be able to communicate with them all your concerns and your expectations.
Find Injection Molding Experts
When you are looking for injection molding experts, make sure you find the dependable one and provides high-quality service. Remember that production costs for injection molding can be expensive; that is why you have to invest in injection molding manufacturers that deliver exactly what you need and make the entire process easier for you. Always do background checks with the company to make sure that they are credible. You can also check reviews from their previous clients to see how good their services are. Before closing the deal, communicate with the company regarding your expectations and ask questions. You will be able to see how they handle their clients and how great their customer support is.
