Injection moulding is a highly versatile manufacturing process used to produce plastic parts and products in large quantities. The process involves injecting molten plastic material into a mold cavity under high pressure and then cooling it to solidify and take the shape of the mould.
The injection moulding process involves:
1. Mould Preparation: The mould, typically made of steel or aluminium, is prepared by cleaning and applying a release agent to prevent sticking. It consists of two halves, the cavity and the core, which define the shape of the final product.
2. Plastic Material Melting: Plastic pellets or granules are fed into a hopper and melted inside a heated barrel by the rotation of a screw. The molten plastic is then forced forward under high pressure.
3. Injection: The molten plastic is injected into the mould cavity through a nozzle, which is connected to the barrel. The high pressure ensures that the material fills the entire cavity and takes the desired shape.
4. Cooling: After the mould cavity is filled, the plastic is cooled to solidify it. Cooling can be accelerated by circulating coolant or water through channels within the mould. Proper cooling is essential to achieve dimensional stability and avoid defects.
5. Ejection: Once the plastic has solidified, the mould opens, and the part is ejected using ejector pins or plates. The part is then removed from the mould, and the mould is closed again for the next cycle.
6. Repeat Cycle: The entire process, including mould closure, injection, cooling, and ejection, is repeated for each cycle. The cycle time can vary depending on the part size, complexity, and material properties.
Injection moulding offers several advantages, such as high production speed, excellent repeatability, intricate part design capabilities, and the ability to use a wide range of plastic materials. It is widely used in various industries, including automotive, electronics, packaging, and consumer goods, to manufacture a diverse range of products.
We are able to mould in a variety of plastics including ABS, Polyurethane, TPU, Polypropylene, Nylon, Acrylic, amongst others.
To aid us in prototyping we can produce short to medium runs up to larger production runs.
Feel free to give us a call or send us an email to discuss your moulding requirements.