Key Advantages Of Using Plastic Injection Molding For The Manufacturing Of Parts
If you are reading this article, chances are you already know a great deal about plastic injection molding, one of the most popular methods for mass-production of high-quality and cost-efficient parts. To put things into perspective, the injection molding technology consists of supplying plastic material into a heated barrel. Afterward, the plastic is mixed and soon after, led into a mold cavity, where it takes the final shape and hardens it into the final product. Plastic injection molding comes with a bag full of benefits against similar plastic manufacturing and processing methods and techniques. The process is way more reliable and straightforward, as well as extraordinarily efficient. Here’s a look at the key advantages of plastic injection molding.
Highly Efficient Fast Production Of Parts
As mentioned in the introduction, plastic injection molding is commonly known as the most efficient form of molding. When compared to similar methods and techniques, injection molding is high-speed, and its high production output rate is through the roof. The speed of the process can vary depending on the complexity and size of the part you’re manufacturing, but in most cases, it takes only 15-100 seconds between each cycle.
With the brief period between cycles, you will be able to produce a larger quantity of molds in a minimal amount of time, increasing both your company’s revenue and profit margins.
Complex Part Design
The plastic injection molding technology can produce millions of practically identical, incredibly intricate parts. Key design elements should be taken into account early in the process, to optimize the performance of high-volume injection molding and maximize the preciseness and quality of the produced parts. The part design plays a significant role in maximizing the efficiency inherent in plastic molding. Once you got the design figured out, the parts can be produced continuously 24/7. Ensure that the design is top-notch since, without a fully developed one, you can make costly processing errors.
Plastic molding professionals around the industry agree that core design elements must exist for the process to work appropriately. These fundamentals include rib design, boss design, wall thickness, corner transitions, gate and weld lines placement, and placed vents.
This technique is nearly perfect for producing very intricate parts. Plastic injection molding allows the maker to incorporate more features at minimal tolerances. When you hold the finished piece in the palm of your hand, you can observe all the little details as bosses, ribs, inserts, side cores, and holes, made with a distinctive feature of the injection tool.
Greater Strenght Of Parts
One of the most significant advantages of this manufacturing process is the enhanced strength of the final products. Depending on the designer’s will, the parts can be flexible or rigid, and the designer will adjust the integrating ribs and gussets according to his/her needs. Every designer needs to understand how the customer will be using the produced part, and to what type of environment the piece will be exposed, so they can design it accordingly.
Knowing the balance of design considerations will help to acknowledge the part’s need for strength and stability. Another key role in the strength of the part is the material selection.
Possibility To Use Multiple Plastic Types Simultaneously
Plastic injection molding for manufacturing parts gives the possibility to use different types of plastic simultaneously. In most cases, this is done with co-injection molding, a plastic injection technology in which different types of plastic are injected into the same mold. The main reasons for using co-injection molding are cost reduction and combining the desired properties of different materials (color, feel, or mechanical properties).
Total Flexibility With Materials And Color
Picking the right materials and colors for a specific project are two of the most critical aspects of producing plastic parts. With so many materials and colors available on the market, the possibilities are almost endless. As polymers advanced over the years, a wide selection of resins to choose from became available. When considering a resin for your project, always think about important resin variables such as tensile strength, impact strength, modulus of elasticity, water absorption, and heat deflection.
Using various coloring systems, plastics can be colored in any imaginable color. Each coloring technique comes with its benefits, properties, and drawbacks. A few of the most frequently used coloring techniques are “salt and pepper” blends, pre-colored resins, and liquid color.
Low Labor Costs
Compared to other plastic molding processes, labor costs in plastic injection molding are relatively low. The plastic molding machinery and equipment run with self-gating, automatic tools to keep operations streamlined and production ongoing, while they require minimal human supervision factor. The whole process is a highly-automated one, whereby the majority of things are performed by robotics and machinery. Automation certainly helps to reduce manufacturing costs, which means getting a cheaper final product for the customer. Besides, post-production labor work is also minimal since the parts usually come out 100% finished upon production.
Low Scrap Rates
The process generates a tiny amount of post-production scrap compared to traditional manufacturing processes. The majority of plastic waste comes from the sprue and runners. Depending on the material and its specifics, any unused or waste plastic can be easily reground and recycled for future use.
Less Expensive Than Plastic Machining
Even though a given mold can be quite expensive to design and create, once the mold is created, you can mass-produce tons of plastic parts and components at a smaller cost. Industry professionals suggest that with large production runs, using plastic injection molding can cost up to 20 times less than plastic machining.