Posts

6 Tips to Avoid Cracking in Custom Plastic Injection Molding

Custom plastic injection molding requires a lot of attention to detail. It is common for cracks to appear on the molded part if one does not know how to avoid them. But knowing those can be difficult without a lot of experience in the field.

One needs a thorough understanding of the reasons behind the appearance of these cracks. Only then can they successfully avoid them. You will find everything you need to know about injection molding cracks here.

What Is Cracking in Injection Molding?

Cracks are not uncommon in custom plastic injection molding, and they appear on the products in different ways. Some cracks are more problematic than others – but all of them are equally annoying. There are internal cracks, corner cracks, and even cracks that start at the gate.

These cracks are exceedingly harmful to the molded object because they cause integrity issues. It gets even worse if you need to fit that molded part to something larger. A competent manufacturer should never allow a compromised piece to pass through their production line.

 

Reasons Why the Molded Parts Crack

Contrary to popular belief, the custom plastic mold design has little to do with the formation of cracks in molded objects. The true culprits of custom plastic injection molding are the ones we have listed below:

  1. Machine

The plasticizing capacity of the machine is a crucial part of crack-free injection molding. A low-capacity machine cannot handle mixing the inserted material volume, leading to cracks. An overly large machine will also degrade the quality as there is a chance of over mixing. So, select the right machine according to your production to ensure optimum efficiency.

So, be vigilant about the plasticizing capacity of your injection molding machine according to your production volume and type.

  1. Mold

The molds play a significant role in custom plastic injection molding. It is usually the most important thing after the main machine. A bad mold can mess up the ratio and distribution of the molten plastic. That will usually lead to cracks and other issues for the finished object.

Burrs and other undercut conditions in the mold can cause cracks too. Ejector designs can also be probable culprits. In other words, you need a professional plastic injection mold design for your products.

  1. Material

Material integrity is essential for custom plastic injection molding. The quality of a molded part depends heavily on the material used in the manufacturing process. High-quality material naturally produces better results.

Reclaimed or recycled plastics usually have lower quality. That can lead to cracks. The moisture content of the material also plays a role. Too much moisture can cause cracks during the cooling process.

  1. Molding operation

Some molded parts require more cooling time than others. A short cooling time usually causes cracks and other defects to these parts. That is also true for molding under too much pressure. Some plastic molds need to work under less residual stress to show the best result.

How to Avoid Cracking in Custom Plastic Injection Molding

Now that you know what’s causing the cracks, we believe you are ready to fix them. Follow these tips to avoid cracks:

  1. Remove Burrs

Burrs are always a nuisance. They can cause deformity and cracks if left untreated. Do a regular inspection to identify and remove burrs to get crack-free molded parts.

  1. Install More Knockout Pins

You need to distribute the stress evenly to avoid agitating any part of the molded object. Try installing more knockout pins. They should help maintain even stress.

  1. Use Less Reclaimed Materials

Reclaimed or recycled materials or pallets tend to have poorer quality compared to new plastic pallets. The reuse of plastic over and over again does slowly wear its polymeric structure every time it is reused.

So, using reclaimed plastics that have gone through too many cycles can cause imperfections in the finished product, leading to cracks. Reduce the amount of reclaimed material you use. If possible, avoid them entirely to get better results.

  1. Remove Moisture

Removing moisture content from custom plastic injection molding will reduce the cracking issue since the moisture inside the materials does harm to the full mixture inside the mold. Dry all your plastics before starting the process.

  1. Increase the Cooling Time

If your cooling time is too short, consider increasing it, and it will give you a much better result. A longer cooling time will keep the mold confined longer, leaving more time for the injection parts to fuse together. That will help create a better outer layer.

  1. Reduce Holding Pressure

Use accurate material volume to reduce the pressure of the molding process. Less pressure will reduce the cracking. You could try with a 50% holding pressure to get a uniform packing. Holding pressure is usually set around 70% for most projects.

Conclusion

Custom plastic injection molding depends a lot on the materials and tools you use. That’s why we always advise people to look for the best plastic injection mold supplier. We at Abery use the latest technology to create the best injection molds in the industry that ensure 100% crack-free injection molding.

Contact us to learn more about how our molds can improve your production.

/by

How Does Abery Keep Growing in Plastic Injection Mold Manufacturing?

injection mold maker

Plastic injection mold manufacturing is currently experiencing a renaissance of new product development due to new technology supporting more reliable outcomes. The versatile nature of mold capabilities is completely tailor-made thanks to the innovation of industry leaders picking up the reigns and developing phenomenal solutions.

As technology and consumer demand force products across all industries to become smaller and more bespoke in design, the need for more custom-made injection molding services is becoming more apparent. Due to automation and 3D modeling, plastic injection mold manufacturing is now rapidly increasing, creating excellent opportunities for this industry to grow and thrive in the modern world.

The Four Major Trends in the Plastic Injection Molding Industry

Like every other sector, new developments lead to higher innovation and adoption. This is apparent with plastic injection mold manufacturers that are embracing benefits and trends resulting in higher revenues and customer satisfaction. These include:

 

  1. Growing Market Concentration – those plastic injection mold manufacturers that are not adapting to market trends or customer demands are being outbid by veteran and flexible companies willing to go the extra mile for clients.
  2. Development of Advanced Tech & Devices – For plastic injection mold manufacturing to meet the growing market concentration, more emphasis is being placed on highly specialized technology that operates using robotics or modern AI automation to reduce operating costs.
  3. Increasing Production Efficiency – data-driven insights into optimization, scrap reduction, and preventative maintenance are increasing the overall efficiency from producing these high-quality outcomes in plastic injection mold manufacturing.
  4. Reaction to Diversified Needs using Powerful Customizations – the more advanced the tools being utilized for production, the greater the capacity for smaller runs of customized molds. That means a more significant share of the target market can be serviced from a single company.

How Abery Grabbed the Chance to Catch These Market Trends

With the writing on the preverbal wall that the only way to thrive in the current marketplace is to adapt with advanced tools and services, a leading provider of plastic injection mold manufacturing, Abery, seized their chance to grow. Some of the methods used to secure this target market include:

 

  • Development of Multiple Services – Abery began offering one-stop solutions to all clients, including custom product design, injection mold making, prototyping, and plastic parts creation. These services earned a greater number of clients that wanted more tailor-made solutions to their product designs.
  • Built a Talented Team – Abery employs some of the best-skilled engineers, designers, molders, and industry experts to maintain and operate their fleet of plastic injection mold manufacturing equipment. This brain trust offers incredible service capabilities to any client seeking a mold solution.
  • Introduction of Advanced Machines – To meet the growing customer demand for customization, Abery invested in state-of-the-art equipment capable of a wide array of plastic mold injections from Bluetooth speakers to anything else a client requires.
  • Shortened Delivery Time – Abery also focused on increasing customers’ satisfaction with smooth and in-time injection molding service. This was accomplished by providing fast delivery of all requested materials, resulting in higher customer appreciation.

 

Client Reviews of Abery’s Products and Services

It is a French-based multinational company providing energy and automation to homes, buildings, data centers, and more. These services combine energy technology with real-time automation. Abery was able to help Schneider with 28 injection molds that are all made with the MOLD MASTER hot runner system. CUMSA special angle lifters were used for certain undercuts, and time constraints were met with a quick approval by Schneider, resulting in a highly satisfied customer and a short lead time.

It provides some of the world’s best-selling automobiles. At that time, their factory in India required new plastic injection mold manufacturing solutions for a ventilation system.  Abery met this demand by offering careful and accurate assembly of each component with a high tolerance of +/-0.02MM. This also included using raw materials made from Nylon GF that operate well in the high-temperature environment so close to the vehicle engine. The result was contributing to the overall function of a high-powered vehicle beloved by consumers everywhere.

 

Where to Get Started

Working with the expert plastic injection mold manufacturing team at Abery has never been easier. To get technical solutions, you can simply fill out the form on our company website or call our support team during regular operational hours. Our highly professional technical team is always ready to listen closely to the needs and designs of each client, resulting in excellent customer service and delivery times.

 

/by

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.

 

/by

Plastic Injection Molded Parts Quality Control 100% Inspection

100% plastic Injection molded parts quality inspection methods
In China,Whether produced after injection products meet quality standards, must be tested, a common quality test methods are the following few ways.

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.

/by