What is injection molding:
Injection molding is a manufacturing process for mass production of parts.It is most commonly used for mass production of the same parts, usually on a scale of tens of thousands or even millions of times.
Why injection molding is used:
The main advantage of injection molding is its ability to concentrate production.Once the machines and molds are ready, the price per unit of product during production is very low.As more parts are produced, prices will fall sharply.Other advantages include:
Injection molding produces a lower rejection rate than traditional manufacturing processes, such as machining, and can reduce a large proportion of the original blank or sheet.It may be slightly higher for additive manufacturing processes with relatively lower rejection rates for 3D printing.Waste plastic in injection molding production usually comes from: sprue, sprue location and any spill from the cavity of the part
The runner is simply the channel through which molten plastic is poured from the nozzle of the injection molding machine to the gate of the entire injection mold.It is separated from the mold itself.The runner is a channel system connected to the gate that directs molten plastic into the cavity of the mold.After the injection mold is filled (typically only a few seconds), the entire molten plastic cools, leaving solid plastic in the runner, gate, cavity itself, and possibly a little overflow on the edge of the part (if the seal is poor).
Thermoplastic materials are materials that can be recycled.Crush gate/runner spout and any scrap parts.These recycled materials are then added proportionally to the new raw material.(Some of the plastic's properties can be degraded as it is molded over and over again.)Recycled materials are used for low quality components that do not require high performance characteristics.
Injection molding is a highly repeatable process.That is, the second part of production will be exactly the same as the first part.This provides good control over product consistency and component reliability in mass production.What are the disadvantages of injection molding:
Because of design, testing, and tooling requirements, the upfront costs can be very high.If you are going to mass produce parts, you need to make sure they are designed correctly the first time.The correct design includes:
Design and then specification the prototype of the part itself
Initial prototype development can be done on a 3D printer, often using different materials (such as ABS plastic)
Design injection molds for initial production
Injection moulds are usually developed in the production of 300-1000 injection product samples.
Inspect and improve any details of the injection mold prior to mass production in the injection mold manufacturing facility.