The following artricles are written by ABERY, a professional custom injection molding manufacturer and plastic injection molding company. From here, you can learn more about ABERY and the latest news about plastic injection molds.

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Custom Injection Molding vs. Compression Molding: What’s the Difference?

custom injection molding

Molding is one of the most common manufacturing processes involving materials such as plastics, rubber, and similar polymers. However, it is essential to note that molding processes vary from each other. For example, custom compression and injection molding, the two most popular molding processes, remain mysterious to some people. And the following guide offers a basic overview of both methods.

injection mold

What Is Custom Injection Molding?

We’ll start with a consideration of how injection molding works. Custom injection molding is the most utilized manufacturing process for fabricating plastic parts. It is a plastics manufacturing technology capable of very high production volumes.

Injection molding is a process that applies the “injection” technique.

The process is carried out by injecting liquid plastic into a stainless-steel mold, where the product is gradually formed under high pressure. The mold is outfitted with various customized cavities to form the product. When the melted plastic has been injected, the material begins filling out the cavities and the rest of the mold. The products are left to cool and are later ejected by pins.

Because of its versatility, injection molding is regularly used for various applications. Everything from automotive parts to small, intricate pieces of surgical equipment can benefit from the process. Its other applications involve medical devices and dental parts, food & beverage packaging, engineering prototypes, cable assemblies, and window and door components.

 

What Is Compression Molding?

Compression molding is more suitable for medium-sized production, usually rubber and silicone. The compression molding tool makes even stiff, high-durometer rubber materials perfectly vulcanized and dimensionally stable.

In general, compression molding is defined by applying heat and pressure. Although this is similar to injection molding, the procedure is completely different. The compression molding process involves heating a mold and placing preheated material inside. After that, the mold is closed to heat and compress the contents into the desired shape. The heating process—also known as curing—ensures the final product maintains integrity and shape. Once cooled, products are removed from their molds.

Compression molding gives strong and durable products. Thus, many industries tend to employ this technique for their applications. For example, some typical compression molding applications include body armor, circuit breakers, plastic dinnerware, and electrical and electronic components.

 

Custom Injection Molding vs. Compression Molding

 custom injection molding vs. compression molding

Injection Molding: Pros & Cons

(1) Advantages:

  • Efficient and Fast Production of Uniform Components

Injection molding is a high-volume production method that can produce millions of parts per machine annually.

Injection molds have shorter cycle times and fewer secondary operations. Additionally, multi-cavity tooling injection molding allows multiple parts to be produced every cycle, which benefits high-volume part production.

  • Enhances Versatility and Customization

Equipped with various customized cavities, this molding type is highly versatile. Besides, consumer products can be easily updated.

  • Low Production Costs

With shorter cycle times and repeatable manufacturing, injection molding lends itself to lower scrap and piece prices due to tooling efficiency.

  • Supports Complex Mold Designs

The desired shape can be simple to complex with the help of computer-aided design for specialized items.

(2) Disadvantages:

Custom injection molding requires a large investment cost. Foremost, the price of the machine itself can be high. Secondly, as it requires very high plastic injection pressures, the mold must be built to withstand these pressures. This adds cost to the tooling. Also, it’s costly for a small number of products. But you can always find a reliable supplier instead of investing in the production lines alone.

Custom injection mold design costs may be high, but keep in mind that these costs are easy to recoup over long and large production runs.

Compression Molding: Pros & Cons

(1) Advantages:

  • Ease of Maintaining Mold Tooling

Since the process often employs high-strength materials, many products created via compression molding are sturdier and more resilient than those manufactured using other molding processes.

  • Low Initial Tooling Costs and Investment

The cost of molding equipment is low, so the initial investment in compression mold is less expensive.

  • Enable More Efficient Color Changeovers

Like injection molding, compression molding is considered to be cost-effective and highly efficient. What’s more, it provides more color changeovers to satisfy unique requirements.

  • Preserve The Mechanical and Chemical Properties of Materials

Compression molding can make composite panels using sheet and bulk molding composites. These panels do not have continuous fiber-impregnated sheets, but rather chopped fiber strands distributed throughout the bulk material.

(2) Disadvantages:

The disadvantage of molding is that mold manufacturing requires secondary machining. And the molding cycle of the whole production process is long and inefficient, and it has a large physical consumption for the staff. Limited by the press, it is most suitable for mass production of small and medium-sized composite products.

custom injection molding

Summary

This article presented the topic of custom injection molding vs. compression molding, explained what they are, and discussed the different attributes of each.

The type of molding best suited for your project will depend on many factors. When those factors point to injection molding as the most effective option, partnering with an experienced service provider makes a significant difference in the outcome that you experience, influencing factors from quality to speed. Find expert help with custom injection mold solutions on your project today from Abery and explore the advanced options available to you now.

 

Top 7 Tips to Maintain the Custom Injection Mold

Plastic molding is critical in any injection molding industry as it is the backbone of many manufacturing processes. Companies have to maintain their custom injection mold frequently as it will help them make the perfect products at an affordable price. As custom injection molds are supposed to work under extreme temperature conditions, only the timely maintenance can increase this machinery’s lifespan and the products’ preciseness.

Why Should You Maintain the Custom Injection Mold?

To be more specific, the reasons why maintaining the mold are as follows:

● To reduce the abrasion of parts

Without maintenance, custom injection molds will get abrasive, resulting in a poor end product. An abrasive nozzle of the mold will not only impact the flow rate of the outgoing material but can also result in the adulteration of the plastic, eventually diminishing the quality of the manufactured products.

● To prolong the service life

Lack of regular or improper maintenance harms the custom injection mold itself, increasing the rate of cracking, deforming, or partial wear, reducing the mold’s lifespan. So, you have to do proper maintenance in order to increase the service life of your molds.

● To save extra expenses for a company

If your molds expire sooner than expected due to poor maintenance, it will be a major setback for any company. Thus, proper maintenance is the only way to increase the life period of any machine and save your company big money.

 

How to Maintain the Custom Injection Mold

Always take care of the following steps whenever you start your mold maintenance:

1. Clean the surface of the injection mold before installation

First of all, always clean the surface of the injection mold before installing it to ensure that no foreign matter is stuck to the surface. Any abnormality at the surface should be immediately removed as it will disturb every batch of the process otherwise.

2. Check all parts of the injection mold after production

You must ensure whether all the parts of the injection mold are being screwed properly or not after production. This is because any ignorance at this stage can even dismantle the machinery during working, which can have hazardous consequences.

3. Clean the injection mold after production

Once you are done with the production, clean every part of the machine to prepare it for the next batch. As injection molding is a batch process, this post-production cleaning is necessary to make the production of the next batch perfect. Without this, the next batch can get messy.

4. Provide rust removal regularly

Providing rust removals to your custom injection mold is crucial as the machine would be rusted otherwise. As the corrosion rate of the metal doubles with every 10-degree increase in the temperature, you must take this step seriously as plastic molding is a heat-intensive process. With so much heat involved in it, rust removal should be a routine activity.

5. Provide burr removal regularly

To make the manufacturing process smooth, you need to remove any dirt, burr, or plastic remaining in the injection molds. The formation of burr in the custom injection molds is normal, typically happening at the mold’s sharp edges. So, you must apply burr removal tactics in order to keep the process perfect.

6. Lubricate corresponding parts of the injection mold

Just like any other machine, lubrication helps custom injection molds as well. When you lubricate the corresponding parts of the injection mold, it minimizes any friction, excessive heat, and even the corrosion of the machine, resulting in a longer life span of the machine and precise injection products.

7. Replace or repair damaged parts

Whenever you see any damaged part in your custom injection mold, the first thing you have to do is to either replace that part or repair it. If you do not do that, the damaged part will destroy other parts of the machine. Worse, you cannot get the precise products in the presence of any damaged part, which makes their repair important.

 

ABERY’s Custom Injection Mold Meets Your Expectation

Abery brings highly precise injection molds that can be used in various applications. Even with tight tolerances of up to +/-0.001MM, the cycle time of these molds is short, increasing the working efficiency. Abery takes the detailed input of every client before manufacturing these molds, making our products custom injection molds in the true sense. We use LKM’s steel, which is one of the most qualitative steel manufacturers. We also provide high dimensional accuracy for products which makes us stand out from the crowd.

Wrapping Up

We at Abery are impacting the decisions of the global industries, as our injection molds are exported to the likes of Europe and America. Our in-house production team manages to inspire the global manufacturers by providing continuous high-profile molds needed for the success of any plastic molding business. Being a mold manufacturer that always pursues perfection, Abery believes that our rigorous designs and high-quality products can win every client’s trust.

 

How to Gain the Perfect Custom Plastic Injection Mold?

Have you ever wondered why consumers and manufacturers most likely beg to differ? It’s because they both have different expectations of the same project. Consumers prefer to have a product compatible with modern age technology and possesses multifunctional features, whereas the manufacturers focus on the accuracy and efficiency of their production lines. The same has happened to the custom plastic injection mold manufacturing market, where mold manufacturers have witnessed a drastic spike in demand for customized plastic injection mold production.

 

What is Custom Injection Molding?

Injection molding is considered to be among the most traditional techniques for manufacturing custom plastic items. The typical process initiates by heating specific synthetic substances (polymers) like plastic adhesives. Once the plastic material has been liquefied by the heat, the molten plastic is then injected into a custom mold involving high pressure. In the end, the molded plastic is cooled down to obtain the final solidified product shape. In other words, the custom plastic injection mold procedure can be summarized in the following six critical steps:

  • Mold clamping.
  • Molten material injection.
  • Dwelling (injection pause while applying pressure).
  • Cooling for solidification.
  • Mold opening.
  • Extraction of the final product.

Especially for making plastic components, custom injection molding is regarded as the epitome of manufacturing techniques for achieving bespoke aesthetics and intricate details. Using this method, manufacturers execute precise mold manufacturing in substantial volumes.

 

Factors to Consider Before Getting a Custom Plastic Injection Mold

Some of the factors to consider before getting a custom plastic injection mold are given below:

  • Parts Shape and Size

Before anything else, take into account the specifications of your project needs. For instance, the particular design of your custom plastic injection mold, depending on the parts’ shape and size, plays a crucial role in producing desired parts. However, you don’t need to worry about the complexity of your ordered design parts because custom plastic injection mold manufacturing is ideal for precise mold production, regardless of the design’s complicated features.

  • Production Quantity

Before getting a custom plastic injection mold, note that most businesses prefer to replicate the same part in bulk quantity since expensive industrial-grade material stirs up the tooling cost for low-volume production orders. Therefore, high-volume production is the right way to go, as the high cost of quality materials and tooling gets compensated by the larger production runs.

  • Parts Material

For perfectly made custom plastic injection molds, the material selection process of parts and hence molds is the key. The industrial-grade, high-quality material will yield maximum results, while the cheap material might naturally do the opposite of good. Accordingly, a professional mold manufacturer would recommend avoiding certain harsh materials (like glass-filled plastic, glass-filled nylon, etc.). Instead, you should select mold materials that provide rigidity and durability to withstand the potential harm that certain abrasive materials can cause the precise mold.

  • Budget

Lastly, here comes the budget for your custom plastic injection mold making. The expenditures you probably want to be concerned about are mostly related to the mold manufacturing tooling cost and design-associated aspects. For instance, the degree of intricate design features decides the correct mold shape and size required to proceed with the part production. However, the top-quality mold manufacturing material would also add to the cost per unit value.

Not only has that, but the specific color and particular texture (surface finishing) demands will also create a spike in your limited budget. Thus, a piece of wise advice here would be to try to measure your non-standard requirements before emptying your pockets all at once.

 

How to Gain Perfect Custom Precise Molds?

Although custom plastic injection mold manufacturing seems quite a straightforward process to operate, in reality, it is the other way around. Even a slight mistake in a single production stage can waste a lot of money on expensive materials and delay the assigned lead time. That’s how many businesses lose a fortune and watch their particular project go down the drain – they fail to recognize the suitable mold manufacturer for the job and end up betting on the wrong horse.

But you don’t need to make the same mistake and face the same consequences. Instead, an intelligent move is only to consult a professional mold manufacturer who is reliable and an expert precise mold supplier, and none else can meet all these qualities better than the one and only Abery.

Why Should You Choose Abery as The Mold Supplier?

There are countless reasons to choose Abery as your precise mold supplier – the following are a few of the benefits that Abery has to offer as your custom plastic injection mold manufacturer:

  • From different injection molding machines to other advanced equipment, we are well-equipped to meet all your precise mold demands.
  • We can quickly achieve quality control and your tighter tolerance requirements with an accurate and accurate mold tolerance capacity of up to +/-0.01mm.
  • Abery relies upon our impeccably skilled engineering team for all your technical specifications and optimized solutions, ranging from design to fabrication.
  • We run a fully optimized control system to monitor every step of the production. Hence, your shorter lead times are always met without any uninformed delays.
  • At last, not only do we have a quick response time of only 24 hours but our exceptional after-sales services are also admired by our valuable customers.

 

Conclusion

To not overlook the significant matter of selecting the proper mold manufacturer, you need to research the precise mold supplier you think thoroughly is the one. Here we would again like to mention that you can’t go wrong if you choose Abery, which is trusted worldwide. Mainly, we specialize in custom plastic injection mold manufacturing, but our remarkable machinery collection also enables us to deal with other kinds of CNC manufacturing operations.

Consequently, we proudly export various absolute best injection molds and parts to technologically advanced places like Europe, the USA, and others. So, what are you waiting for? Get an instant quote today and let Abery’s creative side exceed your imagination.

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.

 

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.

 

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.