Plastic Injection Molding – Keep It Simple

Posted on April 13, 2011 by admin
Auto Parts Mould

Auto Parts Mould

When a part in a piece of equipment or machinery fails, you have to order a replacement part. If your machine is custom-made, then it means that you will need another part to be custom-made. But this might take a while, depending on how intricate the part is and what material it is made from. However, if you already had a plastic mould made for your part, then it is a simple matter of ordering up your part and waiting for it to arrive. Plastic injection molding is a fast way to get the parts that you need in record time, and at a price you can afford.

When the first synthetic plastic was created by scientist Alexander Parkes in 1855, the world of manufacturing had no idea that the plastic mould would revolutionize the way that companies thought about and manufactured parts. Plastic injection molding is fast, easy, and best of all, inexpensive. You can get plastic parts made quickly and inexpensively as soon as you need them, and plastic is notoriously easy to use and surprisingly durable, too. This is why the use of plastic is so prevalent in the manufacturing industry. It is the best solution to a lot of manufacturing needs.

The process of plastic injection molding itself is fairly simple. Plastic granules are fed into the injection chamber of an injection molding machine through a hopper. A reciprocating screw inside the injection chamber makes sure that the flow of the granules into the body of the machine is steady and even. The granules then pass through a heating element to melt the plastic. The melted plastic is then fed into the mold cavity through a nozzle. From the mold cavity, the plastic is injected into the plastic mold itself, where moveable plates apply pressure to make sure that the plastic hardens. It is a simple but highly effective process.

The widespread use of plastic injection molding is due in large part to its ease of use. And the fact that plastic is inexpensive and can be manipulated into just about any shape certainly does not hurt. If you use plastic parts, just be sure to keep a few extra parts on hand so that you will not lose any time on production in case of part failure. By taking advantage of the fact that there is already a plastic mould in just the shape that you need, you can save a lot of time and money.

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crate mould technical points

Posted on December 19, 2010 by admin

1. How to make a crate mould long life running ?
choose the correct steel for mould base and mould main steel. For example, if you need to make a 4 cavities crate mould, then you need to make to use a pre-hardened steel with HRC bigger then 33 for mould base. You have to choose the correct steel or material for the durable mould components.
make the correct harden treatment to each steel piece and make the steel hardness controlled, you can not make it too hard.
the moving area or guiding system of crate mould must be very precise machining processed. Any hand working on it is not acceptable.
if the plastic crate is one-time using, some of the molding company, they use recycled material to make the injection. Then we have to consider about this 2 points. A. how to be sure the small iron piece and the pebbles will not damage the cavities and cores. B. how to avoid the small iron piece and the pebbles enter into the cavities?

2. How to make a crate mould with high speed performance?
Good plastic material filling system, you need a very special hot runner system, because if you need to molding a durable plastic crate, then you need to use low MFI HDPE, such like MFI=4 or even MFI=6…
You need to make the cooling the best optimal effect, for durable plastic crate mould, you need to use mold-max on the molding area with excellent cooling water channel design, for one-time use crate, you need to use tempering steel with excellent cooling system designed…
You need the high speed injection molding machine to run it, the screw RPM should be bigger then 350. in the world, now most of the crate manufacturers they use an accumulator to increase the melt and injection speed.
Plastic crate mould design also is very important, it is better to use a mechanical system onto the crate mould ejection, in this way, you can make the ejection action when the mould opening. Of course, maybe your machine can work with the 2 hydraulic acting in the same time, then you can do the ejection when the mould opening.
For all kinds of mould, the high speed running is based on the mould is précised machining, the movement parts with accurate guided…otherwise, there is none possibility for a mould high speed performance.

3. plastic crate mould’s handle area venting solution:
this is an important issue, as because when the crate was loaded and the people carry the crate, the 2 handle area will be the biggest force focused. If on the mould, this area’s air venting is not perfect, there will be a very obviously jointing line. The damage are always come from this line.

Plastic Mould

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How to Clean Motorcycle Plastic

Posted on December 16, 2010 by admin

Splattered bugs, grease, dirt and road debris can accumulate on motorcycle components and make them appear dingy. Motorcycle plastic parts, such as speedometer covers, tank caps and fenders, require specific cleaning techniques to remove clinging dirt and buildup. Some dirty plastic parts on motorcycles can create safety hazards for drivers; grimy windshields are difficult to see through and dusty speedometer covers are challenging to read. Fortunately, certain solutions and supplies can be used to clean the plastic components on motorcycles.

instructions

1.1
Park the motorcycle in a shaded area. Allow the motorcycle to completely cool.

2.2
Spray the plastic components with water from a garden hose. Rinse all loose dirt and debris from the components.

3.3
Spray general motorcycle cleaner onto the plastic components. Scrub the components gently with a soft wash mitt.

4.4
Rinse the mitt with water frequently to prevent reapplying dirt to the plastic. Continue to clean the plastic components with the motorcycle cleaner until all dirt and debris are removed.

5.5
Rinse the plastic components with water from the garden hose. Dry the components thoroughly with a microfiber towel.

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Types of Plastic Injection Molds

Posted on December 5, 2010 by admin

# Plastic injection molds create objects when melted plastic is forced into mold cavities. They often are used in mass-manufacturing operations to create products such as toys, kitchen utensils, bottle caps and cell phone stands. You can spot items constructed using an injection mold by the “flash lines” of extra plastic around the seams. Here are four major types of injection molds commonly used.
Cold Runner Molds
# Cold runner molds are the most common type of plastic injection molds. These molds use a sprue and runner to inject plastic into each cavity. However, the sprue and runner harden along with the part once it solidifies. Workers then cut these pieces off and recycle them. This can create a problem with waste, which may make them less economical to use.
Two-Plate Cold Runner Molds
# Two-plate cold runner molds are so named because they feature two plates that fit together. There is only one parting plane, and that is where the runner must be located. This is the simplest type of cold runner mold.
Three-Plate Cold Runner Molds
# Three-plate cold runner molds have three pieces, which means there are a pair of parting planes. The three pieces are the runner plate, the moveable plate and the floating plate. The runner plate contains the sprue and half the runner. The moveable plate contains the part’s ejector system and half the part’s geometry. The floating plate contains the other halves of the runner and geometry. The system can be located at either parting plane, and the piece can be gated anywhere on the surface to provide flexibility.
Hot Runner Molds
# Hot runner molds deliver plastic in a different way. While cold runner plastic injectors cool along with the part, the runners in hot runner molds are situated inside the mold and kept at a temperature higher than the plastic’s melting point. This means the sprue and runner never have the chance to harden. This also reduces the amount of wasted plastic. However, hot runner plastic injection molds require more skill and maintenance and have a higher baseline cost. However, they often pay for themselves based upon the material savings.

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How to Build a Coat Hanger

Posted on November 30, 2010 by admin

Have you ever checked into a hotel room on a business trip and discovered a coat hanger-free wardrobe? The simple service of providing a coat hanger appears to be the hotel industry’s Achilles heel. You can always carry around a retractable coat hanger, but you have to remember to pack it in the first place. If you find yourself caught away from home, and don’t fancy turning up to a business meeting looking as if you have just been involved in a road rage incident with an angry elephant, you might want to consider crafting a make-shift coat hanger.

intructions

Gather the Necessary Materials.
1.1
Decide how sturdy the coat hanger needs to be. You can do this by determining the weight of the object that you intend to hang. Constructing a coat hanger for a lightweight shirt is another matter entirely from making a coat hanger for a heavy, woolen coat.

2.2
Find materials to use as the coat hanger base. The base will need to be approximately 12 inches long; an ideal base would be a wooden or plastic ruler, a sturdy (i.e. not damp) wooden stick, or a piece of A4 cardboard tightly rolled into a cylindrical shape. If you do have to resort to a wooden stick, make sure that it doesn’t have anything on it that could scratch, stain or otherwise damage your clothes.

3.3
Find materials to use for the structure. When collecting the appropriate materials to produce the coat hanger structure, remember to consider the weight of the garment that you intend to hang on it. A section of garden twine, parcel string, wire or even a washing line can be used.

4.4
Construct the coat hanger base. Take the coat hanger base and cover it with a plastic bag to protect your item of clothing if necessary. Fasten the bag to the base with adhesive tape.

5.5
Attach the base to the structure. You should cut a section of twine approximately 36 inches long. Tie the two ends of the twine to the two ends of the coat hanger base, to form a structure that looks like a miniature swing.

6.6
Construct the neck. Holding the coat hanger so that the base hangs parallel with the floor, begin twisting the twine in the middle section. Tie off the section that you twist, making sure that your coat hanger is level with the floor.

7.7
Construct the hanger. Once you have tied off the neck, tie another knot or two to stabilize it, leaving a loop of twine at the top, above the base. You should be able to hang the coat hanger by your finger from this loop, and it should rest evenly. Once you are satisfied that it is parallel to the ground, cut the loop at the very top.

8.8
Attach your coat hanger to the wardrobe railing. Where the loop has been cut in two, take these two ends and fasten them securely around the railing. Test the coat hanger by trying to hang your item of clothing on it.

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Cooling system design in plastic mould

Posted on November 22, 2010 by admin

In plastic mould, cooling system is very important. A good cooling system can shorten the cycle time and improve the production efficiency. If it cannot be even cooled, the product will be out of shape and even crack. Thus the cooling system should be designed according to product’s shape, wall thickness and material. Now let me introduce the basic principle during cooling system design.

1. The number of water channel should be as more as possible and the cross section area of the channel should be as large as possible.

In order to make the temperature distribution more even and prevent the uneven shrinkage and emerge of residual stress, we should add more water channel and use large cross section area if it is allowed.

1. The distance of water channel from cavity surface

When the product’s wall thickness is even then the distance should be similar. However, if the wall thickness is uneven, the water channel should be closer to cavity surface in the thick part and the distance between water channels also can be small. Generally, the water channel is about 10-15 mm far away from cavity surface.

2. The distribution of entrance and exit of the water channel

There are two problems should pay attention to about the distribution: one is about the cooling in the sprue gate and another is temperature difference between entrance and exit.

When the material filling in the cavities, the temperature around gate is most high and the more far away from the gate the lower the temperature is, thus, the cooling should be enhanced around the gate, that is to say, the entrance of the water channel should be arranged near the gate.

In order to reduce the temperature difference in cooling system, the water channel also should be arranged according the cavity shape.

1. Cooling water channel should be designed in the direction of plastic shrinkage, especially of the plastic with high shrinkage like PE, PP.

2. Cooling water channel should be avoid the part where weld line easy appear, this part has low temperature, if we set the water channel here, it will make it more easy to appear the weld line.

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How are Storage Boxes Made?

Posted on November 18, 2010 by admin

If you look at a plastic storage box closely, you’ll probably notice there are no seams or joints. In other words, it was made all in a single piece. The process behind this is called injection moulding. It is the same process used to create almost everything we use that’s made of plastic. The process is surprisingly simple, making moulded plastic products very inexpensive to produce; thus, the relatively cheap price for storage boxes.

In the injection moulding shop, a mould maker (sometimes called a tool maker) uses a set of drawings to produce a mould. Most moulds used for plastic are made of aluminium or steel. A series of holes will be included to allow a clear path for the plastic material to travel into the mould cavity. When he’s finished, the mould cavity will be the exact shape and size of the storage box.

From there the mould travels to a test production area where it is installed in an injection moulding machine for initial set-up. Engineers need to determine how much plastic to inject into the cavity to get the desired product. Tiny plastic beads are fed into the machine through a hopper, where they are melted, mixed, and injected into the mould. Pressure gauges, flow meters, and chronometers all take measurements during this process. When the engineer is satisfied with the finished product, he creates a detailed fact sheet containing all the settings needed to produce the plastic storage on the shop floor.

The mould is then transferred to a production machine and put to work; duplicate moulds are sometimes made for large orders. Operators will tend to the machines, remove the finished storage boxes, and trim any debris left by the injection process. And now you know how plastic storage boxes are made.

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Auto Door Mould ADM-3

Posted on November 14, 2010 by admin

Auto Door Mould ADM-3

Auto Door Mould ADM-3


Auto Door Mould 1. Spectification:Based on customers requirement.
2. Mould Material:NO45, P20,2738,718H etc
3. Product Material: PP,PC,PA,POM,ABS,PE etc
4. Cavity Quantity:single/multi cavity
5. Seriver:We can supply both mould and products.
If you have any new projects to quote,please sent to us, we will give you competitive price.

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TV Mould

Posted on November 7, 2010 by admin

The rapid development of TV Mould manufacturing technology has become an important component of modern manufacturing technology part. If mold CAD / CAM technology, laser rapid prototyping mold, precision mold forming, precision machining technology of mold, mold in the design of the finite element method, boundary element method to flow, cooling, heat transfer in the dynamic simulation technology, mold CIMS technology, has developed mold technology and CNC technology, DNM, cover almost all the modern manufacturing technology. ?

Modern mold manufacturing technology to speed up information-driven towards, increase manufacturing flexibility, agile manufacturing and the systematic integration of direction. ?

1. High-speed milling: the third generation of tooling ?

High-speed milling process not only has high speed and excellent machining accuracy and surface quality, but also compared to the traditional cutting of low temperature (workpiece only increased 3 ?), heat distortion, and therefore suitable for temperature and thermal deformation sensitive materials (such as magnesium alloy, etc.) processing; also due to cutting force is small, thin and rigid applicable to poor machining; rational use of tools and cutting parameters, enables hard materials (HRC60) and processing a number of advantages. Therefore, high-speed milling is still a hot topic at present, it has more agile, intelligent, integrated direction, became the third generation of modeling technology. ?

2. EDM milling and “green” product technology ?

Electrical machines from abroad of view, whether in performance, process indicators, intelligence, automation have reached a very high level, currently the new trend is for foreign electrical discharge milling (EDM machining technology) research and development, which is an alternative to the traditional processing of the cavity with the electrode forming the new technology, it is simple to use high-speed rotary tubular electrode for three-dimensional or two-dimensional contour machining (CNC milling, as the same), so no longer need to make complex forming electrode, which is obviously a major area of EDM development. ?

Recently, the company launched a EDSCAN8E Mitsubishi EDM machines have witnessed new progress. The machine can automatically compensate for electrode wear, the Windows95 machine developed for the specific CAM system, with AutoCAD and other common CAD linkage, and can carry out online accurate measurements to ensure high precision machining. To determine whether abnormal or incomplete processing of shape, CAM system can achieve simulation process. ?

Technological progress in the EDM, while the safety and protection EDM technology more and more attention, many electric machines are considered security technologies. Currently the EC has provided no “CE” mark of machine can not enter the EC market, while also increasing emphasis on the international market security technology requirements. ?

Currently, the main problem EDM machine is radiation harassment, because of its safety, environmental impact is greater, more and more attention in the international market, “green” products where, as the leading equipment mold processing machines EDM ” green “product technology, will be the next problem to be solved. ?

3. A new generation of die CAD / CAM software technology ?

At present, Britain, the United States, Germany and other countries and a number of universities and research institutes in China mold software development, with a new generation of die CAD / CAM software for intelligent, integrated, mold manufacturability evaluation and so on. ?

A new generation of software should be built from a mold die design practice have summarized a large number of knowledge. After a systematic knowledge and scientific order, stored in a specific knowledge base in engineering and mold can easily be invoked. In support of intelligent software, CAD is no longer mold of traditional design and calculation method of imitation, but under the guidance of advanced design theory make full use of experts in this field extensive knowledge and successful experience in the design result will have a reasonable and advanced. ?

Mold a new generation of software to three-dimensional thinking, intuitive sense to design mold structure, the generated three-dimensional structure information can be easily used to mold manufacturability evaluation and numerical control machining, which requires die software Parametric feature modeling, molding process simulation, numerical control machining process simulation and exchange of information and organization and management reached a considerable degree of perfection and a higher level of integration. To measure the level of the degree of software integration, not only depends on functional modules are complete, to examine whether these functional modules is to share the same data model, whether the formation of a unified global approach dynamic database
To achieve integrated management and sharing of information to support the mold design, manufacturing, assembly, inspection, testing and commissioning of the entire process. ?

Mold manufacturability evaluation function in the role of a new generation of die software is important, both for multi-program screening, but also on the mold design process, rationality and economic evaluation, and modify the basis for mold designers. ?

In the new generation of die software, manufacturability evaluation include mold design and manufacturing cost estimates for Assembly Evaluation mold, mold manufacturing process evaluation components, the die structure and formability evaluation. ? new generation of software should have features for assembly because the function of the mold assembly through the structure can only be reflected. Assembly-oriented design methods, the mold assembly is no longer a simple assembly of parts one by one, the data structure can describe the functions of mold, mold can define relationships between components assembly features, parts and components to achieve the association which can guarantee the quality of the mold.
?

4. Advanced rapid tooling technologies ?

1) Rapid Prototyping (RPM) developing very rapidly, China has reached international level and the progressive realization of commercialization. Has commercialized the world’s rapid prototyping technology mainly SLA (stereo lithography), LOM (layered split manufacturing), SLS (selective laser sintering), 3D-P (3D printing). ?

Tsinghua University, introduced the first American company 3D SLA250 (three-dimensional laser lithography, or photosensitive resin curing) equipment and technology and conduct research and development efforts over the years, many improvements, perfect, launched “M-RPMS-type multi- Functional Rapid Prototyping System “(with laminated object manufacturing-SSM, melt extrusion-MEM), which is China’s own intellectual property rights of the world’s only rapid prototyping process has two systems (national patent), has good cost performance. ?

2) multi-point forming technology is highly adjustable punch plate group instead of the traditional mold for forming another surface of advanced manufacturing technology, multi-point forming system for CAD / CAM / CAT Technology as the main means of rapid economic realize the automatic three-dimensional surface shape. Jilin Industry University assumed the non-die forming of the national key scientific and technological projects have been independently designed and manufactured with international advanced level of multi-point forming equipment. ?

The technology of China and the United States, Massachusetts Institute of Technology, Tokyo University, Tokyo Institute of Technology compared to the theoretical study and practical application of all in the lead is now moving to promote development in the application.

Three) resin stamping dies for the first time in the trial of domestic cars has been successfully applied. FAW Die Manufacturing Co., Ltd design and manufacture of 12 sets of resin molds for a new trial modification of small red car, the 12 sets of molds are the trunk, hood, front left-right sub-panels and other large complex covering parts of the drawing inside and outside Die for, the main features of the mold surface to CAD / CAM processing of the master model as a benchmark, using the Swiss Ciba forming high-strength resin casting, punch and die clearance of imported special wax and accurate control of die size and high precision , the manufacturing cycle can be shortened one-half to two-thirds
Manufacturing cost savings of about 10 million yuan (12 sets of molds). For our trial and small-volume production cars opened up a new way, is a national initiative. Swiss Ciba experts believe that up to 90 international standards. ?

5. The scene of the mold detection ?

Mold development, increasing demands on the measurement. Precision coordinate measuring machine, has long been subject to environmental constraints, rarely used in the production site. Basically, a new generation of coordinate measuring machine has a temperature compensation and the use of anti-vibration material, to improve the dust control measures, environmental adaptability and reliability, so that it can be easily installed in the workshop used to achieve the characteristics of the measurement site . ?

6. Mirror polished mold surface engineering technology ?

Mold mold surface polishing technology is an important part of engineering, mold manufacturing process is an important post-processing technology. Currently, the domestic mold polishing to Ra0.05?m polishing equipment, abrasives and abrasive technology, you can basically meet the need, but to throw to Ra0.025?m mirror polishing equipment, abrasives and abrasive technology is still in the exploratory stage. With the injection mold mirror large-scale applications in production, die mold polishing technology has become a key issue. As the domestic polishing technology and materials, there are still some problems
So fool the camera lens, such as injection molding, CD, VCD disc and tools for high transparency and a large part of the injection mold is still dependent on imports. ?

It is noteworthy that the surface of die polishing equipment and polishing process is not affected by the impact of technology, but also by the degree of mold material mirror This is not enough attention, ie, polishing itself constrained by the mold material. For example, 45 # carbon steel made with injection molding, the polishing to Ra0.2?m, the obvious visible defects, dropped, and can only continue to increase in brightness, while the roughness has no hope of improving it is the current domestic production in the mirror mold mold materials are imported, such as Sweden, a win 100 136, Japanese Datong PD555 other mirror can be satisfactory degree. ?

Mirror mold material is not only chemical composition problem, the main thing is when asked by vacuum degassing refining, argon protection ingot, vertical continuous casting and rolling, soft forging a series of advanced technology, so that mirror mold steel with internal defects, little impurities fine grain size, high dispersion, fine metal grain size, size distribution and a series of advantages, to achieve die steel polished to mirror the requirements.

Injection Mould, TV Mould

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china mould maker is few professional overmold and overmolding maker in china

Posted on November 3, 2010 by admin

Overmolding, an injection molding process, has drastically changed the aesthetics, design, and functionality of consumer products over the last decade. It is increasingly finding its way into the medical market as device makers realize its potential benefits. Although known for creating texture, commonly called soft touch, the process offers much more, including ergonomics, two-color aesthetics, brand identification, and property modification. The process can add functionality to a product (e.g., noise and vibration dampening, waterproofing, and shock absorption) and increase a product’s value.

Overmolding falls into the broad category of multimaterial molding, along with coinjection, two-shot, and sandwich molding. The basic premise of multimaterial molding is to take economical advantage of two or more materials with uniquely different properties by incorporating them into a single molded component.

In this article, the first material shot is referred to as the substrate or substrate material, the second material as the overmold or overmolded material.

Overmolding Options

In overmolding applications, an overmold is injection molded around, over, under, or through a substrate material to complete the final part. This injection can be done with a multishot process or by insert molding. Usually, the overmolded material is an elastomeric resin.

Multishot Process. Multishot molding is a good choice for medical devices if the configuration of the overmold permits it. The process requires a special press with two or more barrels so that different resins can be shot into the same injection molding tool. The barrels, arranged parallel to each other or in an L configuration, feed resin through common or separate injection points into the tool. When one common injection point is used, the process is called coinjection, and the result is a composite part in which a skin encapsulates a core resin. Separate injection points result in an overmolded part, which is produced by molding one component on top of the other, creating a layered structure.

But multishot molding is not possible for all products. The required volume for the overmold must be able to be created by moving a slide or by rotating the mold core to another mold cavity. Another option involves shuttling the mold core to another press.

Insert Molding. A product such as a completely overmolded handle would require insert molding. To be completely overmolded, a substrate must be taken out of the tool and placed into a different core and cavity to create the volume for the overmold material. During this process, a separate tool should run in the same or a different-size press (depending on shot size). Usually, the overmold portion of a part is significantly smaller than the substrate. Preheating the substrate might be necessary to bring its surface temperature closer to the melt temperature of the overmold, so as to reach optimum bond strength.

In-Mold Assembly

Sometimes overmolding is called in-mold assembly, since the resulting part essentially assembles two materials rather than creating a layered structure. Both individual components and assemblies can be overmolded. But regardless of the application, achieving a mechanical or chemical bond between the substrate material and the overmolded component is crucial.

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