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The characteristics of precision injection molding is: the size of the injection molded parts with high precision, small tolerance.

precision injection molding
precision injection molding

To achieve the requirements of precision injection conditions must be met:

(1) the mold material is better, rigid, cavity dimension precision and template between positioning accuracy is higher, lower surface roughness.

(2) to adopt precision plastic molding machine.

(3) to adopt precision molding process.

(4) to choose suitable for precision injection molding process of the material. Commonly used precision molding materials have several: POM, POM = CF (carbon fiber), PNM = GF (glass fiber), PA \ FRPA66 (enhanced PA), PC, etc.

Precision injection process can ensure the size ,that molding is the important way to control the shrinkage of injection molded parts, including: thermal contraction, disguised contraction of molded parts, orientation and compressed contraction and elastic recovery.

Common injection molding features not high than precision injection molding, the size of injection molded parts are typically can be assembled into standard, requirements for the appearance of the injection molded parts is relatively high, if necessary, may use the second processing (oil, for example) to improve the appearance of defects. Ordinary injection molding don’t need to use special precision injection molding machine, also do not need to specially designated materials, general common thermoplastics can be used to production. So ordinary injection molding technology is widely used in modern plastic industry.

Precision injection molding process

In the process of precision injection molding, the raw material is pre- loaded into the box.
Automatic feeding (in the form of particles) to the injection molding machine hopper.
Melt the raw material in the barrel and inject the mold under high pressure.
The molten polymer is allowed to cool and solidify, and is removed from the mold.
If necessary, used water to clean, dry with a hair dryer. Then they are shipped for packing inspection.

Medical supplies and equipment for precision semiconductors as well as data storage, consumer electronics, medical and automotive industries in the production of precision injection molding of other high precision plastic parts.

Various tonnage of automatic precision injection molding machine (from 80 to 650 tons), our products meet the customer’s strict size, functional and aesthetic requirements.
We also provide medical products, the formation of non dust production plant, clean the packaging of various products, molding parts without pollution risk.

SELECT A GOOD PRECISION INJECTION MOLDING MACHINE
To buy a high precision injection molding machine, the impact of injection molding machine selection factors include the following:
1 die size (length * width * height), weight, special design
2 kinds of plastics (pure or many kinds of plastics)
3 injection product size (L, W, H, thickness), weight and so on.
4 molding requirements: such as quality conditions, production speed, etc….
According to the above information, you can choose the machine that suits you.
First, select the type of product and plastic material
Second, the mold can be placed on the machine, to determine the size of the tie, the height of the mold, the minimum size of the mold is appropriate.
Third, you can take out the product.
Switch trip is more than two times the height of the opening and closing of the product.
The jet’s journey is enough to spray the product.
Fourth, the clamping tonnage is determined by the plastic materials and products.
Fifth, the weight of the injection depends on the weight of the product and the mold cavity.
Sixth. Injection speed: thin-walled products always require high injection speed.

Compared with the traditional technology, Cn-moulding has higher precision injection molding and more perfect performance, which is often supplied to electronic information engineering, medical devices, packeging, cars, machinery, hardware, apparatus，timepiece industry, weapons and aerospace, etc. Therefore, it will become a revolution between parts molding and processing.

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Nowhere is this more evident than in the rise of the little guy, as the number of manufacturers producing and selling 3D printers has grown to nearly 100 manufacturers this past year, up from 62 in 2015 and just 49 back in 2014, according to a new report from Wohlers Associates Inc., the leading additive manufacturing and 3D printing consultancy.

Tags: 3D Printing, additive manufacturing, custom manufacturing, KASO Plastics, short run production
BRIDGE THE GAP FROM PROTOTYPE TO FULL-RUN PRODUCTION WITH 3D FDM PRINTING

Posted on: Mon, Jul 21, 2014
KASO Plastics 3D Printing
3D PRINTED PROTOTYPING
3D Printing has been a popular technique for rapid prototyping for years, but recently end uses for the technology have also expanded, becoming an excellent option for OEMs looking to bridge the gap between prototype and full production.

Tags: 3D Printing, 3d printing prototyping, FDM printing, KASO Plastics, plastic injection molding, plastics manufacturing, Rapid Prototyping, short run production
NEW OPPORTUNITIES FOR 3D PRINTING AND SHORT RUN PRODUCTION

Posted on: Thu, Jun 26, 2014
3D Printed Plastic Part
Rapid prototypers around the globe have been utilizing 3D printing to create manufacturing prototypes that help prove out design concepts and test part functionality. But rapid prototyping is only the beginning when it comes to the opportunities that are now available for 3D printing.

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That’s because no matter how brilliant a design is, certain production constraints can take a promising design and turn it upside down fast. If these constraints are not addressed early in your product’s development, they can turn into much larger problems by the time you move into production, leaving you in the unenviable position of having to choose between two similarly unpleasant alternatives – sacrificing product quality or blowing your production schedule. Either choice can leave you with additional costs.

Some of the risks associated with skipping Design for Manufacturing include:

Unstable production processes
Unstable part dimensions
Part variability
Poor quality finished parts
DESIGN FOR MANUFACTURING: WHAT’S INCLUDED
An experienced Engineering team can provide plenty of DFM assistance to address design complexity, provide suggestions to help simplify product designs, and make them easier to manufacture. This reduces unnecessary design iterations as well as reducing the risk that products designs will be too complex and therefore cost prohibitive to produce.

At KASO, we believe Design for Manufacturing is an invaluable tool for our customers. That’s why KASO’s Engineering team goes even further to guide customers through the process, sometimes going so far as to provide on-site design assistance when needed, working closely with your team to ensure product designs are 100% ready for production.

WHY MATERIALS SELECTION IS SO IMPORTANT
The right materials can make all the difference when it comes time to manufacture. When you work with a knowledgeable manufacturer, you will have the opportunity to review all possible material options. Here at KASO, our team is often able to suggest substitutes that help customers reduce their costs and even improve the quality of finished products.

So remember: Making necessary changes to your products is much easier, more efficient, and more cost effective the earlier you do it. Design for Manufacturing makes successful manufacturing a reality.

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But alas, it seems some pressures never change.

Lower costs! Higher quality! Greater productivity! The refrain remains the same but the pressure only increases. That’s why you need a plastics manufacturer with plenty of tools to help you combat these challenges and stay competitive. How do we do it here at KASO?

MANUFACTURING AUTOMATION
Automation is a tool that KASO increasingly employs to help speed up manufacturing and improve product quality. Our dedicated staff are always on the lookout for new opportunities to speed up production and improve part quality by automating various production tasks. Starting by clearly defining YOUR parameters for success, our team can help you find new automated solutions that will get you to your end goal faster.

EARLY SUPPLIER INVOLVEMENT
Are you someone that thinks meetings are a bore? Maybe that’s because you haven’t taken advantage of the Early Supplier Involvement process before. Early Supplier Involvement is a process that helps you get the very most out of your product development partner by combining our companies’ strengths earlier in the design and prototyping stages of your development. By doing so, we are able to provide suggestions that will improve your manufacturing and reduce your manufacturing costs wherever possible.

RAPID PROTOTYPING WITH 3D PRINTING
3D printing has received its fair share of buzz in recent years, and for good reason. Not only can 3D printing provide functional prototypes that are up to 80% as strong as the actual finished parts will be, but it means we can create these prototypes in a matter of hours in-house. What does that mean for your products? Faster design iterations, greater design flexibility, and less time to market for your products. Testing your parts prior to full run production has never been easier!

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injection molded plastic in china
injection molded parts inspection in china

full inspection
It was called full inspection is individually tested for injection products, we have talked about “full” refers to the number of all the plastic parts produced, rather than the entire value of the quality characteristics tested. In determining the test items,Test costs are generally low, the implementation of all product inspection is to have a higher quality requirements.

Such as plastic parts Dimensions test is easier and can be fully tested, and the requirements of the position and some plastic parts crucial, a great impact on the quality, but also the need for full inspection. Not plastic parts for each test must be carried out in full, as it cost too much time-consuming and laborious. Usually occurs when the following conditions using full inspection.

1) found that more unqualified plastic parts, plastic parts or the whole batch are unqualified, the need for follow-up products for full inspection.

High single value

2) injection products, even when a scrap will bring great losses.

3) If the product quality problems, give people life safety or safety hazard when great.

Injection molded plastic sampling inspection
The so-called sampling inspection,, is from a group of randomly selected plastic part of the test conducted. By this test section of plastic parts extracted to make the evaluation of quality of these plastic parts. Compared with the full inspection sampling inspection, it tested a small number of plastic parts, low-cost test, test speed. Sampling inspection and batch size of the number of samples, volume, sample quantity; small quantities, less sampling; as long as the appropriate number of samples, the test results have a high accuracy. Usually by random checks in the following cases.

1) Some of the Injection molded plastic parts that mechanical and physical properties need to destructive testing, this will bring damage to the plastic parts.

2) more than the mass production of plastic parts, plastic parts produced quantity particularly large, want to save test time and test costs.

3) the production of raw materials in Injection molded plastic parts, there are a lot of raw material is powdered, granular or liquid form, the raw material for these multi-use sampling. Compared with the full inspection sampling inspection, although there are a small number of test and low test cost advantages, but also the following problems: First, when the second installment of the plastic parts, even after sample testing has been considered qualified, can not believe that this batch of plastic parts plant each plastic parts are qualified, which may also exist a very small amount of non-conforming product. Second, the sample tests will inevitably appear judgmental errors, this is the vast majority of qualified products, due to sampling bias, but judged unqualified; or could have been substandard goods, has become qualified. Therefore, in order to determine the probability of error is controlled within a reasonable range, often need to coordinate the use of mathematical statistics methods.

In short, the full inspection and sampling test has its own characteristics, and applications and problems also vary, depending on the circumstances test methods should be chosen to adapt. Mostly due to the injection mold products for mass production, it is more to take sample tests

Machine Inspectioninjection molding molded plastics inspect
Parts are initially inspected directly out of our molding machine. Our engineers are trained to identify and rectify the following defects:

Sink marks that form when the outer plastic shell hardens before the internal plastic has had an opportunity to cool
Short shots caused when there is an inadequate amount of plastic material to fill the mold
Burn marks caused by trapped compressed air during the molding process
Flash marks, which is the excess plastic that extends from the end of the molded part.

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molding flash

When designing your plastic parts, as far as possible to reduce the thin-walled section, resulting in a thicker wall section, the entire product into a uniform wall thickness of the parts.

The rapid change in wall thickness is the most common cause of flash, due to the production process of plastic materials under pressure, through the liquid state to fill the injection mold.

If the product design in the thick and thin wall thickness of the part is necessary to exist, the use of different injection point to help the flow of materials.It is very important to control the location of the gate, especially in the tight tolerances of the plastic parts.

Flash of an injection molded part can happen for several reasons – slight variations in the material, pressure, speed, injection mold process and/or problems with the tooling itself.

For example,The sprue bushing is one of the reasons that can not be ignored.Need to know is that nozzle contact forces can range from 5 to 15 tons.If the thermal expansion makes the critical distance sleeve “growth” out of the parting line, the nozzle contact force enough to move the mold side, resulting in flash generation not only mold precision will produce flash operation,The operation of the injection molding is the same as the source of the problem, the mold should take advantage of the length of the hot runner bushing inspection, into the standard of each production.

Through analyze every stag of the injection molding process at our company, and ensuring consistent stress free manufacturing of your custom plastic parts.Our process engines allow us to produce tight tolerances parts for all of our customer.

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