The injection molding production process

The injection molding process is usually comprised of 6 steps:

  1. The clamping: An injection machine contains 3 parts – the injection mold, the clamp and the injection unit, among which, the clamping unit keeps the mold at a certain pressure, so as to ensure the consistency of the outputs.

A mold is usually made up of 2 parts.

  1. The injection unit: It refers to the part where the plastic pellets are fed into the hopper located at the top end of the injection unit. These pellets will be loaded into the main cylinder, where they are heated at a high temperature until they are melted into liquids. Then, inside the injection unit, a screw will turn and mix the already liquefied plastic. Once this liquid plastic has reached the ideal condition for the product, the injection process will start. The plastic liquid is forced through a running gate, of which the speed and pressure are controlled by a screw or sometimes a ram dependingon what kind of machine you are using.
  2. The dwelling: It represents a pause in the process when certain pressure is applied to guarantee that each of the mold cavities has been filled thoroughly. It is such an important step within the process that if the mold cavities are not filled properly, it will lead to scrap of the units.
  3. The cooling: This process step allows the mold to cool off for a required period of time. If this step is performed too hastily, the units will probably stick together or get deformed when it is taken out of the machine.
  4. Mold opens: The clamping unit will open to separate the mold. The molds which are often the most important individual part during the entire process are used over and over again, and the tooling of them can be very costly.
  5. The ejection: The finished product is ejected from the injection mold machine in the end. Generally speaking, a finished product will continue to be on a production line or be packed and delivered to a production line as a component of a larger product, e.g. the steering wheel of a car.

In daily life, the products that involve the application of injection molding are used every day by each of us. If it were not for injection molding, many cars would not be sold at such an affordable price. However, this process also has some disadvantages. The machines are very costly and therefore involves a lot of capital investment. When designing the parts, we must keep the production process in mind, because the process is not deemed economical for short-run productions.

Nevertheless, the disadvantages are outweighed by the greater benefits, which include the speed at which the parts are produced, the relatively low labor costs and minimal material waste. Even, the finished parts usually require no more finishing.

If you are interested in our service or in need of any technical support, please feel free to let us know. We would be happy to share what we know about plastic injection molding with you and provide the exact economical plastic injection molding solution you are looking for.

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Chinese Mold MakersTake Up More Than Half of Global Mold Business

Once the consulting service provider KPMG conducted a study which showed that with a total sales revenue of 5.7 billion USD in 2002, China had already overtaken Germany and the US to become the biggest machine tool maker in the whole world, making it a viable base for mold sourcing and manufacturing thanks to its skilled labor force and the relatively low cost level.

The study which is entitled China Machine Tools Market, aims to get a deeper insight into the market and the greatest issues of concern to the market players in the moldmaking industry. During the study,the consulting firm KPMG has referred to a quantity of authoritative sources of information and spoken to market players from both home and abroad. In addition, it also performed an investigation into leading machine equipment manufacturers in Germany to find out how they are responding to the opportunities and challenges in the Chinese market. Since most respondents had already made their presence here, they were able to offer first-hand views on the greatest concerns to their business in China.

As the result of the study indicates, though the local firms are gradually closing the technological gap and improving product quality and performance, there will still be a sizeable market for importing high-end machine tools into China. However, transnational players will need to proceedcautiously as how to effectively engage in the Chinese market, considering the fact that the competitions and marketing situations are witnessing fast changes.

In recent years, half of the machine tool production has been consumed by the automotive sector, while the aircraft sector, aircraft maintenance and repair in particular, is expected to become another predominant market in China.

Along with China’s gradual integration into the world economy, competition in the country has been intensifying. Local machine tool makers have become increasingly experienced when choosing theirmachine tools, leading to the increasing demand for NC tools. And yet, the low-end market is overcrowded with domestic players, which has created great pressure on prices. On the other hand, foreign products still dominates the mid- to high-end markets with cutting-edge technologies and superior quality.

To sustain their competitive edge, Chinese domestic manufacturers are involved more actively in R&D of new products and more acceptive to taking advantage of joint ventures and mutual cooperation to leverage new technologies.

Since Germany is one of the leading machine tool consumers as well as exporters in the whole world, KPMG also performed a survey of German machine toolmakersfrom August to November 2003. Amongall the respondents surveyed, 98% of them were currently doing business with Chinese partners either via export (52%), established production facilities (36%) or licensed production (15%).

The study also found that most of the respondents attached greatimportance to the Chinese market and would like to expand their businesses here.And, all the surveyed considered IP as one of the most critical business factors.

Lastly,more than half of the respondents thought that when doing business in China, the two major business issues to be solved were recruitment and the regulatory environment in the market.