How to Shorten the Injection Molding Time?

The time required for different types of plastics like POM and nylon to finish an entire injection molding cycle is known as the Molding Time. It is basically the integration of the injection period and the cooling period of the process. This cycle is directly related to the productivity of the process.

The shorter the injection molding time, the better it is for the smooth pushing forward of the project. To reduce the injection molding time, someone decreases the temperature of the mold and the heating barrel. If you do this, the cooling time will naturally fall. But the actual influence of the low temperature is far more than that – it may bring unwanted results, such as degraded quality of the molding parts.

Shortening the injection molding time can be a bit tricky, but if you do it correctly, you’ll surely be satisfied with the results!

The Process of Injection Molding

To begin with, let’s look through the whole process of injection molding to see which step can be optimized to decrease the time. There are multiple processes by which precision injection molding can be performed. A few of them are listed below:

1.    Mold clamping

Mold clamping is a technique where two parts of a mold are held together with the help of a clamping unit. The next step is to inject the melted plastic into the mold.

While this is going on, the clamping unit squeezes the two halves together. This clamping process can take from a few seconds to a few minutes.

2.    Plastic injecting

The molding machine intakes plastic pellets and uses the heat that surrounds the barrel to melt them. This melted plastic then goes into the mold. The injection is assumed to be stopped when around 95% of the mold is full.

3.    Pressure holding

After the mold is filled with melted plastic, the clamping unit applies uniform pressure to the two halves throughout the entire time. This ensures the perfect shape of the desired object.

The pressure can be required to be applied for a couple of minutes to even a few hours, depending on the object’s size.

4.    Cooling

Later, the mold has to be kept steady to allow the elements to cool down. This also doesn’t take long unless you’re molding something large.

5.    Release

When the mold has cooled down, you can instantly open it. This doesn’t require much time. But it needs a certain amount of force to release the molding part as the plastic part is compressed and gets stuck to the body of the mold.

How to Shorten Injection Molding Time?

The injection molding time can be reduced if some steps are taken. Those steps are discussed below:

1.    Fasten the clamping

The mold clamping has to be done precisely. This will affect the entire molding time because if the clamp isn’t holding the mold perfectly, it will cause the comparatively low-temperature air to disrupt the process, increasing the molding time. The procedure of accelerating-uniform speed-decelerating operation when clamping is the most important movement to create a perfect molding part.

2.    Decrease back pressure

Backpressure is a term in the injection molding process that usually means the build-up of pressure in the back of the screw that forces it to a particular point. At this point, if the mold is opened, the material will drip out of the mold, causing waste and degrading the quality of the molding part. The backpressure has to be reduced dripping and shorten the plasticization time.

3.    Shorten pressure holding time

Reducing the pressure holding time can be an essential step that can help reduce the injection molding time. The thing you can do is terminate the process the moment the cold runner becomes solid. This will shorten a considerable amount of time spent in this process.

4.    Adapt different ejection methods

Different ejection methods can be helpful for you if you’re looking to reduce injection molding time. The Pneumatic ejection method is a lot faster than the Hydraulic one. However, the Electric ejection method is the best of them all as it’s the fastest.

5.    Lower the temperature of mold and heating barrel

Another thing you can do is decrease the cooling time of the process. This will surprisingly reduce the large amount of time that was being wasted.

Why Should You Choose Abery’s Precise Injection Mold?

Our precise injection molds are made with the latest and greatest innovations in the industry. The excellent designing techniques adapted in Abery’s Precise Injection Mold manufacturing process can help your production time to decrease drastically and with minimal errors.

Moreover, we also offer you the opportunity to customize your creation. High-precision plastic injection molding helps designers be more specific with their designs. The results are almost perfect and consistent practically all of the time.

Our precision injection molding technique allows improved and detailed designs to come alive. Even very sophisticated designs can be transformed into physical objects.

 

Conclusion

The short injection molding time is the reason why Abery can deliver the products in such a short period. The precision injection molding technique of Abery not only provides the mentioned advantages but offers so many other benefits, including in-time project reports, precise molds, and satisfying customer service.

Our strive-for-perfection attitude and expertise on plastic injection have attracted a lot of famous brands which keep long-time cooperation with us, including Honda, Lascar electronic, and Lennox.

Abery is undoubtedly worthy of coming into your consideration which can help reduce your injection molding time and cost. We show great sincerity to invite you to be our next partner, so contact us now to design your molds today!

 

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Top 3 Things You Need to Know About Custom Plastic Injection Molding

Do you ever wonder how the parts with irregular shapes are made and why they fit tightly? The answer turns out custom plastic injection molding, which boosts as the production process gets more precise. It is already applied in many fields, such as households, health machinery, automotive, electronics, and more.

The versatility of the custom plastic injection molding is what makes it so accessible and perfect for all kinds of different applications. And to make the most of it, you need a thorough introduction to custom plastic injection molding, which is where this article will help. The illustration falls on three aspects: importance, application, and production process.

Importance of Plastic Injection Molding

The importance of custom plastic injection molding is now higher than ever. One of the biggest drivers of the growth of this type of molding process is the versatility and the benefits that come with it.

  • Ability to Product Complex Geometry

Experienced plastic injection molding manufacturers can produce complex geometry that has no deviations. You will need advanced equipment and also a team of experts as well. It means that no matter what your needs are, a specific plastic mold can be designed, tested, and made at scale.

  • Durability and Strength

Custom plastic injection molding is more durable to withstand strain and abuse compared to molds from yesteryears. What’s more, the right material of the mold can be chosen from a wide range according to the needs and requirements.

  • Cost Savings

OEMs can reap the benefits of lower costs. That will increase their profit margin or offer their products at a lower price to the end customers. The process can be designed for DFM, which stands for Design for Manufacturability. The OEM and injection molding teams can work together to bring costs down overall.

 

Multiple Applications of Custom Plastic Injection Molds

As we mentioned a couple of times, there are many applications of plastic injection molds. Customer plastic injection molds can be used in industries like:

  • Electronics

The electronic industry can use plastic injection molds to design different sorts of custom electronic goods for the masses. From smartphones, gaming consoles to novelty gadgets, different critical components, and outer casings can be made from custom plastic injection molds.

  • Medical equipment

Since plastic injection molds can be used to manufacture any part and are accurate to within 0.0005 centimeters, they can be used in precise machines like medical equipment. The mold will be carefully designed to cater to the strict specifications that medical equipment often requires.

  • Automotive

The automotive industry is another area where it can be used. Making a durable and cost-effective mold for the mass production of automobile parts not only meets the need of vehicle production but also brings a large convenience to car repair.

With all the information above, the next thing you need to know is how a custom plastic mold is made.

Copyright photo from https://unsplash.com/photos/xoxnfVIE7Qw

Process of Producing a Custom Plastic Mold

There is a step-by-step process to making plastic injection molding parts. And as with most things, it first starts with the design.

  1. Mold design

The mold design process is crucial——Here is where you hash out all the ideas and talk about the different needs for your project. A poor design can ruin your custom plastic injection molding project. And it will also cost more compared to a well-designed DFM design.

  1. Mold manufacture

After the design process, it is time to manufacture the mold, where the expertise of a molding supplier usually shows. There are mainly five steps to produce a mold:

  • CNC machining: In this procedure, the digital milling machine uses a rotating cylindrical tool to cut workpieces accurately, versatilely, and fast to get the desired shapes.
  • EDM machining: EDM machining stands for electro-discharge machining or spark-machining. In this process, a particular shape is obtained by using electrical discharges. This process is also called wire cutting.
  • Lathe Machining: Lathe machining is a precise machining procedure. It can perform operations like changing the surface roughness, weak resistance, visual properties, and chamfer the mold’s features.
  • Mold Fitting: This is one of the most critical processes of custom plastic injection molding. It requires expertise where mold pieces are put together to form a perfect shape or mold.
  • Mold Polishing: This technique helps increase the smoothness of the mold and makes the products easier to demold. That can be done by horning which is usually conducted by whetstone, sandpaper, polishing paste, and wool wheel.
  1. Mold Trials

The last stage in the custom plastic injection molding process is mold trials. You need to make sure that the mold you designed and manufactured works perfectly and as intended.

Without any trials, you might overlook critical and non-apparent design or manufacturing mistakes, which can be very costly down the line.

At Abery, we can design, produce, and examine products to provide the most suitable and cost-effective custom plastic injection molding for you.

 

Conclusion

With state-of-the-art machines and expertise, we at Abery, a professional plastic mold maker, provide tailored services for clients with various requirements. We offer not merely professional products but attentive service and fast delivery. So don’t hesitate to enjoy the custom injection molding service by contacting us! We are eagerly waiting to hear from you.

 

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Mexico plastic exhibition 2019

Mexico plastic exhibition 2019

ABERY take the Mexico plastic exhibition 2019 at April 2nd. Welcome our esteemed customers to visit us at our booth No. 4318, E hall.

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Inner motivated training for our sales team

Inner motivated training for our sales team

For improving the motivation for our sales team, We took part in a special training course last week. Our colleagues are very excited during that class. they did do good training there. they got emotional suggestions and proposals form the teacher. they will do work with the way they learnt from that training in future.

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Competition Is Heating Up In The Additive Manufacturing Market

It seems 3D printing, long heralded as the “next big thing” for manufacturing, has finally come into its own.

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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Design For Manufacturing

DESIGN FOR MANUFACTURING: A CRUCIAL STEP TOWARDS PRODUCT SUCCESS
Design for Manufacturing is a crucial element of any successful push towards launching new products, ensuring designs are optimized for the manufacturing process.

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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How Today’s Manufacturing Tools Will Help You Stay Competitive?

THE EVOLVING MANUFACTURING LANDSCAPE
The plastic injection molding market continues to evolve, creating greater specialization and more technological advancements than ever before.

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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