What Are The Advantages Of Gas Assist Molds?

Gas assisted injection molding is a process for producing big plastic to get rid of complicated designs as well as excellent ornamental surface area coatings. Continue reading to get more information about the advantages of gas assist molds.

Gas Assist Molds

Smooth surfaces

 

Gas assist injection molding likewise produces much smoother surface areas to attain the preferred style. After the plastic product has currently been expelled from the machine, it can already be fit for market distribution with really couple of alterations or secondary procedures needed.

With a smoother surface, producers do not need to make changes to the device– i.e. lowering stress, temperature level, and even the place of the gates. This is since gas assisting can already fix many of the problems that may result on the surface of the plastic. Smoother surface areas use a more aesthetically appealing as well as smooth design.

High functionality

 

In the regular injection molding process, there is no gas channel to transmit a low-pressure nitrogen liquid. This suggests that the process may take a lot longer time because there is no element that is quickening the flow of the material into the mold. As a result of the absence of this part, the material can be prone to bending as well as higher inner stress.

With gas-assist, nevertheless, internal stresses are substantially minimized in the resin, leading to a much faster and freer-flowing product. Integrated with properly maintained mold and mildew dental caries, any kind of product resulting from gas-assisted injection molding will conveniently be better compared to the alternative.

Fewer products needed

 

Depending upon the kind of material utilized, injection molding pellets can cost as much as $5 USD per kg. This, along with the expense of purchase and maintaining the elements of the injection molding device are currently costly alone.

Knowing this, makers take advantage of gas assist when they desire a reduced volume of material to be used. This produces cost-beneficial end results for both the maker as well as the end-user.

Using less product can help them save added resin pellets for future usage without giving up the top quality. When a consumer desires a model to be done, on the other hand, they could almost request the much more cost-friendly and also economical gas assist process.

Minimizes fabrication defects

 

There are lots of common sorts of injection molding flaws– from something as minor as circulation lines as well as staining to something as complex as distortion and warping.

To avoid these issues from occurring, injection molding tools operators need to embark on a series of modifications on the device. For instance, they might intend to create another mold and mildew layout, increase/reduce stress and also temperature level, and even utilize various resins entirely.

Gas assist offers a reliable as well as all-around service to these flaws. As claimed before, the low-pressure nitrogen gas is constantly and also uniformly sent to the molten material. It permits the product to be firmly pressed as well as portable itself onto the walls of the mold tooth cavity. The outcome– a high-quality product that’s devoid of stress and takes the intended design and shape of the producer.

 

Gas Assist Molds

 

Lighter

 

Plastic has actually been a preferred material for several sectors as a result of its lightweight residential or commercial properties. With the right tools and also maker handy, it’s feasible to come up with acrylic, HDPE, polyethylene, and even polytetrafluoroethylene injection-molded items that are less thick than the typical material yet can still be used in functional applications.

Like the materials over, materials that have undergone gas assist injection molding are far lighter in weight in contrast with the typical injection molding procedure. The main consideration for this is that the procedure uses up much less area and material, leading to a sturdier and also extra long-lasting product that is not also cumbersome.

Critical takeaway

 

Several benefits of gas assist injection molding consist of the following: much better dimensional quality, enhanced efficiency, much less product, lighter product weight, smooth surface areas, and much less warping.

For both manufacturers as well as end-users, the gas assist injection molding strategy uses a number of advantages. Before deciding on whether or not the gas assist procedure is the right one for you, establish your item needs as well as factors to consider such as production as well as procurement expense, parts needed, high quality of the material, and so forth.

Improved sizing quality

 

The procedure of setting up multiple or particular gas channels in a single plastic injection molding equipment is absolutely nothing brand-new. As a matter of fact, gas assist is widely made use of in producing specialty items– specifically those that have special dimension styles and patterns.

Ribbed plastic items, as they’re called, are the result of a finely-tuned gas assist injection molding strategy. This process is one of the most efficient selections for generating these stylized products as a result of the boosted dimensional precision as well as quality that it provides. You’ll frequently locate everyday materials like container caps, water drums, containers, as well as much more.

 

We are a gas assist mold supplier, please feel free to contact us if you need them.

Three Questions You Need to Consider before Choosing Precision Molding

If you need a plastic part molded with extreme precision—for example, to ensure there’s no air leak between two molded sections or to be certain there’s no visible seal gap line—you likely require precision molding. The difference between a typical injection molded part and a precision molded part is the tolerance, or acceptable range of variation in dimension: While the majority of injection molded parts have a tolerance of +/- .005″, precision molding holds tolerances between +/- .002″ and +/- .001″ (or less, in some cases).

Let’s say, for example, you’re planning to manufacture a military projectile. In order for the projectile to fit properly in the firearm, handle the acceleration when it’s launched, and explode on impact, it requires very high precision.

If your application requires precision molding, you can’t leave anything to chance—so you’ll want to ask yourself the following three questions before you begin the process:

 

1. Have you selected a plastic material with low shrinkage?

The plastic material you select for your part makes a big difference in whether you’ll be able to do precision molding. For example, polypropylene has a shrinkage range of +/- .014″ to +/- .022″, with an average of +/- .018″. This is a wide range for shrinkage, which makes hitting a specific tolerance extremely difficult. If you’re molding a toothbrush (which commonly uses polypropylene), dealing with shrinkage isn’t a big concern, as the toothbrush will function appropriately regardless of whether it’s slightly bigger or smaller than its counterparts. Acrylonitrile butadiene styrene (ABS)—another common thermoplastic polymer—has a much narrower shrinkage average of +/- .006″. That gives you a much better chance of hitting a tighter tolerance, but it still won’t reach the +/- .001″ or +/- .002″ tolerance needed for a precision part.

One way to hit high tolerances with your plastic material is to add glass or another filler resin (like carbon fiber or mica) into the material. This can minimize shrinkage and warp by providing more structure in the material. For example, if you include long glass fibers in a polymer material, the part will shrink more perpendicular to those fibers.

2. Have you determined which areas of the mold require precision?

Because precision molding is more expensive than typical injection molding, be certain which aspects of your part require tight tolerances—and whether those tolerances can be achieved through injection molding—before moving forward. For example, a surgical handle may only require precision for the piece that will connect with a pin, not the entire handle. Identifying your precision requirements from the get-go ensures you’ll get what you need without wasting money. In the case of the surgical handle, your injection molding partner may advise you to add the tolerances you need through tooling after the injection molding process is complete.

3. Can the mold manufacturer you’ve selected tool with high precision?

The process of creating plastic parts with tight tolerances begins with a high-precision mold. If each plastic part you create is not identical, you won’t have a precise product—and a precise mold ensures there’s no variation for each part. Because of this, it’s extremely important to select a mold manufacturer who understands the slow, steady process of building a high-precision tool. Keep in mind that selecting a mold manufacturer that specializes in rapid tooling is likely not your best option, as the goal of rapid tooling is to finish the mold quickly—but not necessarily precisely.

Let’s get your precision molding project started

We have years of experience in precision molding, and would love to answer any and all of your questions. You can either contact us with those questions, or, if you’re ready to get your project started now, simply contact us and request a free quote.

Advantages And Disadvantages of Two-shot Injection Molding

There are a variety of manufacturing methods used to create products using plastic polymers, including two-shot injection molding, compression thermoset molding and extrusion. While all of these are viable manufacturing processes, there are several advantages to this process that make it the top choice for many plastics manufacturers. The process is relatively simple; one material is injected into a mold in order to make the initial section of the product, followed by a second injection of a secondary material that is compatible with the original material. There are three good reasons many manufacturers use this method of manufacturing plastics or polymers.

Advantages of two-shot injection molding

Two-shot injection molding  is cost-effective

The two-step process needs only one machine cycle, rotating the initial mold out of the way and putting the secondary mold around the product so that the second, compatible thermoplastic can be inserted into the second mold. Because the technique uses only one cycle instead of separate machine cycles, it costs less for any production run and requires fewer employees to make the finished product while delivering more items per run. It also ensures a strong bond between the materials without the need for further assembly down the line.

Enhanced product quality

Two-shot injection molding enhances the quality of most thermoplastic items in several ways:

Improved esthetics: Items look better and are more appealing to the consumer when they are crafted of different colored plastics or polymers. The merchandise looks more expensive if it utilizes more than one color or texture
Improved ergonomics: Because the process allows for the use of soft-touch surfaces, the resulting items can have ergonomically designed handles or other parts. This is particularly important for tools, medical devices, and other hand-held items.
Enhanced sealing capabilities: It provides for a better seal when silicone plastics and other rubbery materials are used for gaskets and other parts that require a strong seal.
Combination of hard and soft polymers: It lets you combine both hard and soft polymers for outstanding comfort and utility for even the smallest of products.
Reduced misalignments: It can greatly reduce the number of misalignments when compared to over-molding or more traditional insert processes.
Complex mold designs: It enables manufacturers to create more complex mold designs using multiple materials that can’t be effectively bonded using other processes.
Exceptionally strong bond: The bond created is exceptionally strong, creating a product that is more durable, more reliable, and with longer life.

Versatility

Product manufacturers favor a wide range of applications for two-shot injection molding, including automotive interior parts, medical equipment, tools, and toys. It allows manufacturers to combine various materials and colors to create a strong and attractive final product. Some materials can be effectively combined with this process, including silicone and thermoplastics, nylon and thermoplastic elastomers, or hard nylon and soft-touch materials.

Two-shot injection molding can solve your company’s product production difficulties. An experienced plastic manufacturer can guide you from concept to finished product and ensure a cost-effective solution.

Producing an assembly with multiple components

Compared to other methods of plastic molding, two-shot is ultimately a more cost-efficient way of producing an assembly with multiple components. Here’s why:

Part Consolidation: Two-shot injection molding reduces the number of components in a finished assembly, eliminating an average of $40K in development, engineering, and validation costs associated with each additional part number.

Improved Efficiency: Two-shot molding allows multiple components to be molded with a single tool, reducing the amount of labor needed to run your parts and eliminating the need to weld or join components after the molding process.

Improved Quality: Two-shot is carried out within a single tool, allowing for lower tolerances than other molding processes, a high level of accuracy and repeat-ability, and reduced scrap rates.

Complex Moldings: Two-shot injection molding allows for the creation of complex mold designs that incorporate multiple materials for functionality that cannot be achieved through other molding processes.

Disadvantages of two-shot injection molding

1) High tooling costs and long setup lead times. Up-front costs are high due to the design, testing, and tooling required. There is the initial design and prototyping (probably via CNC or 3D printing), then the design of a prototype mold tool to produce replicas of the part in volume. Lastly, and only after extensive testing during both stages, you can finally inject mold a part.

2) Part design restrictions. Plastic parts must be designed with injection molding consideration and must follow the basic rules of injection molding, for example:

Avoid undercuts and sharp edges as much as possible

Use uniform wall thicknesses to prevent inconsistencies in the cooling process resulting in defects like sink marks.

Draft angles are encouraged for better de-molding.

Don’t forget, because tools are typically made from steel or aluminum, it can be difficult to make design changes. If you need to add plastic to the part, you can make the tool cavity larger by cutting away steel or aluminum. But in order to take away plastic, you need to decrease the size of the tool cavity by adding aluminum or metal to it. This is extremely difficult and in many cases might mean scrapping the tool (or part of it) and starting over.

Also, the weight and size of the part will determine the tool size and necessary press size. The larger the part, the more difficult and expensive it will be.

3) Small runs of parts can be costly. Due to the complexity of tooling, and the necessity to rid the machine of all previous material before the next product can be made, the setup time can be quite lengthy. Therefore small runs of parts have traditionally always been thought of as too expensive to injection mold.

 

We are a professional plastic injection mold manufacturer. If you have projects on hand, please feel free to contact us via [email protected]

Difference between Thermoset & Thermoplastic Injection Molding

Thermoplastics and thermosetting plastics are two separate classes of polymers that are widely used in the process of injection molding to create products of various types. Both these categories of plastics possess different properties and characteristics. Hence, choosing the right category of polymer, between the two, is of paramount importance to achieve the expected results when used in applications.  Most of the injection molding service providers usually receive a question from their clients about the differences between thermoplastic and thermoset molding process. Here, in this post, let’s see thermoset & thermoplastic injection molding comparison.

 

Defining Thermoplastic and Thermosets

Before we go deeper into the topic, it is important to understand the two terms thermoset and thermoplastic. Let’s first find out what are thermosets and thermoplastics.

What are Thermosets?

Thermoset plastics “set” after they cure and are generally stronger than thermoplastic materials. Initially, the polymer is a liquid or soft solid, which becomes rigid later when cured. Owing to their high mechanical and physical strength, resistance to heat, corrosion, and mechanical creep, thermosets are used in a variety of applications. A few amongst the common thermoset materials used in the injection molding process include alkyds, epoxy, phenolic, polyimides, thermoset polyester, and so on.

What are Thermoplastics?

In contrast to thermoset, thermoplastics liquefy and become pliable when heat is applied. Thermoplastic polymers can be reheated and reprocessed many times, which is impossible when it comes to thermosets. Usually stored in the form of pellets prior to the molding process, these categories of polymers can withstand multiple re-shaping without causing any damage to the material. They possess high strength, shrink-resistance, flexibility, high-Impact resistance, and chemical resistant, among others. A few amongst the common thermoset materials used in the injection molding process include ABS, nylon, PET, polypropylene, polyethylene and TPE, among others.

Difference between Thermoset & Thermoplastic Injection Molding

The way thermosets are molded differs with respect to thermoplastics in several aspects and both the categories require varied treatment during the injection molding process. Let’s check a few differences when molding thermosets and thermoplastics.

Where and How They’re Used

The differences inherent to thermosets and thermoplastics make them uniquely suited for differing applications.

Appliance fabrication may require a thermoset such as epoxy — the material’s high-impact resistance, microbial resistance, and general inert properties are ideal in the kitchen and cooling environment. Conversely, a thermoplastic such as polyethylene makes a great packaging film, since the material shrinks and conforms to the packaging when heated.

As a general rule, thermosets are often affiliated with manufacturing and utilities — appliances, electrical applications, and anything else involving heat that may otherwise warp thermoplastics. Thermoplastics, on the other hand, are broadly diverse and used in everything from aerospace fabrication to consumer goods and toys. The nature of the polymer used depends on the final application.

 

Now that you know how thermoset injection molding differs with respect to thermoplastic injection molding. With the information provided in the post, you would be able to make a judgment on the type of polymer category you should opt to produce molded parts. However, just knowing the differences between the materials won’t be enough, instead you would need an injection molding service provider who can mold your parts as per the right specifications provided. Partner with leading injection molding companies like WIT MOLD who own a comprehensive working knowledge regarding thermoplastic vs thermoset molding.

Insert Molding VS. Overmolding: What’s the Difference?

 INSERTED MOLDING TOOL

 

There are various sub-processes within injection molding that add further capabilities to this already versatile technology. This article will explore insert molding vs overmolding and the advantages of each.

Injection molding is a broad term used to describe one of the most important processes in the manufacturing industry. It’s a process that requires a mold, typically made of metal with a cavity in the shape of the desired part. Molten plastic is injected into the mold and ejected. The process repeats to produce thousands of identical parts. It’s safe to assume that every large-volume plastic part on the market has come from an injection molding machine because the benefits of using injection molding for production are numerous. These benefits include low cost per part, short cycle times, extensive materials, and compatible, in-tolerance parts.

Various sub-processes add further capabilities to this already versatile technology. This article will specifically explore insert molding vs. overmolding and the advantages of each.

What is Insert Molding?

Insert molding is a subset of injection molding techniques similar to overmolding where metal components are placed into a mold cavity before the actual plastic injection. The insert is precisely positioned inside the mold either manually or by a robotic arm. The mold then closes, and plastic is molded over the insert, creating a single part.

One of the most common applications for insert molding is the creation of metal attachment features for fasteners. Fasteners enable assemblies to be securely assembled and disassembled without product damage. Heat-set threaded inserts are molded into plastic to reduce the risks of thread damage during installation.

Insert molding can also eliminate the need for fasteners by including the necessary metal parts in the mold, thus firmly securing the parts into a single bonded component.

Why Choose Insert Molding?

Insert molding is a versatile process that has numerous benefits, some of which are listed below.

Reduced Assembly Cost – An injection molding machine can create thousands of parts per day. Such economies of scale can significantly reduce the cost of the individual parts. In a typical CNC machining, sheet metal, or additive manufactured part, any required assembly can be a major bottleneck. Insert molding can be used to eliminate assembly and thus maximize cost savings.

Part Performance – In general, plastic parts are less robust than their metal counterparts. However, plastic offers other benefits such as reduced cost, superior design flexibility, and lighter weight. Combining both metal and plastic materials into one part can capitalize on the benefits of both. Metal inserts can be used where strength and stiffness are required and the remainder of the part can be made of plastic to reduce weight. Moreover, plastic parts do not fare well against wear and tear and metal inserts add an element of durability to parts to withstand any kind of cyclical loading.

What are the Disadvantages of Insert Molding?

Despite the many benefits of insert molding, a few disadvantages need to be considered before choosing to use this sub-process.

Multiple Manufacturing Technologies – Insert molding can involve a 2-step manufacturing process. If the inserts are a custom design and not off-the-shelf parts, they will need to be manufactured using a metal forming process like CNC machining. These metal forming techniques are often significantly more expensive per part than similar, fully injection-molded processes. In some cases, the metal parts can be manufactured via die casting or MIM (metal injection molding). This can reduce the overall cost of the metal inserts but cannot eliminate the insert molded unit’s increased cost because parts with metal inserts will typically cost more than a part that is only plastic.

Increased Part Complexity – If a custom-made metal insert is required, the designer must be aware of both technologies’ design for manufacturability (DFM) principles and understand how best to integrate these technologies into a single practical part.

What is Overmolding?

Overmolding is essentially a type of insert molding. However, overmolding vs. insert molding is, as the name suggests, plastic is molded over another molded part. The first component is made inside an injection mold, and it is then placed into a second mold to add the over-molded material. This technique combines multiple plastics for either practical or aesthetic purposes. For example, one might use different durometer plastics to mold a softer plastic over a more rigid one to make a part easier to grip. Using multiple colored plastics in an over molded part can also distinguish the product from other brands. Overmolding is regularly used on the handles of tools like screwdrivers, power drills, or toothbrushes.

Why Choose Overmolding?

Overmolding is a versatile process that has numerous benefits:

Increased Material Flexibility – Overmolding allows designers to leverage the benefits of multiple types of materials to create complex parts with different properties, add visual complexity, or add haptics.

No Adhesives Required – Overmolding allows different materials to be fused in the mold, thus eliminating the need for glues or other permanent bonding methods. This increases the part’s overall durability and reduces assembly costs.

Embedded Seals – Overmolding offers the option of molding soft seals into parts. An example would be an electronics enclosure that needs to be IP rated. Usually, the part will have a groove into which an o-ring can be installed later. However, it is far more cost-efficient and robust to permanently mold the seal as an integral component.

What are the Disadvantages of Overmolding

Despite the many benefits of overmolding, a few disadvantages need to be considered before deciding to use this process.

Multi-Step Process – Overmolded parts are made in a two-step process. This increases part cycle time and is thus more expensive than molding a single part with no overmolding. This also requires two tools or a complex two-shot mold with increased upfront costs. However, when the alternative is to create two separate injection-molded parts and then assemble them after the fact, overmolding becomes a value-added solution.

Debonding – Bonding two different materials together in an injection mold runs the risk of delamination. This typically happens if the temperatures are not in the optimal range for the specific material combination. In some cases, mechanical interlocks may be required when materials cannot be reliably bonded together using heat.

Conclusion: Choosing Between Insert Molding, Overmolding, or Injection Molding

Injection molding, which includes the sub-processes of insert molding and overmolding, is a versatile and low-cost manufacturing production process that is used in the large majority of consumer products. Injection molding often results in the lowest cost per part when compared to other manufacturing techniques like CNC machining and even 3D printing.

Once injection molding is chosen for a specific application, the next step is often whether to use insert molding, overmolding, or just stick with plain injection molding. When trying to weigh the advantages of the processes, it is important to accurately define the product application. Each of these processes has specific use cases that are suited to different product types. It can be difficult to gauge which process will best suit your particular product, so it’s good to get expert advice early on. Contact WIT and We will help steer your design decisions in the right direction so that you can choose between insert molding vs. overmolding or just injection molding.

injection mold

Common Defects Of Injection Molds And Their Solutions

An injection mold is a tool for producing plastic products and for giving them a complete structure and precise dimensions. Read on for more information about common problems and solutions for injection molds.

 

injection mold

 

A mismatch between mold and injection molding machine

Causes:

1. Positioning ring position is not correct, size is too big or too small.

2. Wrong position and size of the ejector hole of the mold; wrong position and size of the forced pull reset hole.

3. Mold width size is too big; mold height size is too small.

Solution:

1. Adjust the ejector hole position and size; adjust the reset hole position and size.

2. Replace the positioning ring; adjust the position and size of the positioning ring.

3. Change the tonnage of a large injection molding machine; increase the thickness of the mold.

 

Bad quality of parts

Causes:

1. The fit-gap is too large.

2. Poor glue walking, trapped air.

3. Ejector pin is too small, uneven ejection.

4. Too small bevel, burr, hardness is not enough.

5. Uneven injection pressure, insufficient strength of product form.

6. Processing error.

7. Far from the gate, low mold temperature.

Solution:

1. Trim the gate, pressure uniformity, strengthen the product strength.

2. Reasonable adjustment of clearance and grinding work part of the parting surface.

3. Improve the gate, increase the mold temperature.

4. Add local glue, add exhaust.

5. Re-processing.

6. Increase the ejector pin, evenly distributed.

7. Repair burr, increase slope, nitriding.

 

injection mold

 

The parts are difficult to fill and difficult to take

Causes:

1. The pouring system is blocked, the runner cross-section size is too small, the gate arrangement is unreasonable, and the gate size is small.

2. The limit stroke of the mold is not enough, the extraction stroke of the mold is not enough, the ejecting stroke of the mold is not enough.

Solution:

1. Check whether the limit, core extraction, and ejection strokes meet the design requirements and adjust the strokes that do not meet the requirements.

2. Check the runner and gate of each section of the pouring system, and fix the parts concerned.

 

Mold opening and closing ejecting reset action is not smooth

Causes:

1. Slanting ejector, ejector pin sliding is not smooth.

2. Mold frame guide column, guide sleeve sliding is not smooth, with too tight

3. Reset spring elasticity or pre-pressure is not enough.

Solution:

1. Increase or replace the spring.

2. Repair or replace the guide pillar, guide bush.

3. Check and repair the slanting top, ejector pin.

 

Mold water transportation is not working or water leakage

Causes:

1. Water sealing rubber ring and water pipe joint are not sealed enough.

2. The mold water channel is blocked and the inlet and outlet water pipe joints are connected in the wrong way.

Solution:

1. Check the cooling system inlet and outlet water pipe joints connection and each section of the waterway, repair the relevant parts.

2. Check the water sealing rubber ring and water pipe joints, repair or replace the parts.

 

WIT MOLD is a very professional mold design and mold manufacturer located in southern China and has passed the ISO2009:2015 international quality Our injection molding process can be customized according to your unique project. If you are interested, please feel free to contact us.

Advantages And Differences Of Two Shot Injection Molding

There are a variety of manufacturing methods used to manufacture products that use plastic polymers, including two-shot injection molding, compression thermoset molding, and extrusion. Although all of these are viable manufacturing processes, this process has several advantages that make it the first choice of many plastic manufacturers. The process is relatively simple; inject one material into the mold to make the initial part of the product, and then inject a second material that is compatible with the raw material. Many manufacturers use this method to make plastics or polymers for three good reasons.

 

Two-shot injection molding is cost-effective

The two-step process only requires one machine cycle, the way the initial mold is rotated and the product placed around the second mold, so that a second, compatible thermoplastic can be inserted into the second mold. Because this technology uses only one cycle, rather than a separate machine cycle, any production operation cost is lower, and fewer employees are required to manufacture the finished product while delivering more projects per run. It also ensures a firm bond between the materials without the need for further assembly down the line.

Two-shot injection molding

Two-shot injection molding

 

Strengthen product quality

Two-shot injection molding improves the quality of most thermoplastics in the following aspects:
Improved aesthetics. When products are made of different colored plastics or polymers, they look better and are more attractive to consumers. If more than one color or texture is used, the product will look more expensive.
Improve ergonomics. Because this process allows the use of a soft-touch surface, as a result, items can have ergonomically designed handles or other parts. This is especially important for tools, medical equipment, and other hand-held items.
When silicone plastic and other rubber materials are used for gaskets and other parts that require a strong seal, it provides a better seal.
It allows you to combine the outstanding comfort and practicality of hard and soft polymers with even the smallest products.
Compared with overmolding or a more traditional insertion process, it can greatly reduce the number of dislocations.
It enables manufacturers to create more complex mold designs using multiple materials that cannot be effectively bonded by other processes.
The bond created is very strong, creating products that are more durable, more reliable, and have a longer lifespan.

 

Versatility

Product manufacturers favor two-shot injection molding, with a wide range of applications, including automotive interior parts, medical equipment, tools, and toys. It allows manufacturers to combine various materials and colors to create final products that are both strong and attractive. Some materials can be effectively combined with this process, including silicone and thermoplastics, nylon and thermoplastic elastomers, or hard nylon and soft-touch materials.
Two-shot injection molding can solve your company’s product production dilemma. An experienced plastic manufacturer can guide you through the process from concept to finished product and ensure a cost-effective solution.
We are Two-shot injection molding suppliers. Please feel free to contact us if you need or want to know about our products.

Pros And Cons Of Thermoset Injection Molding

Weighing the pros and cons of the molding process for your composites can help you determine whether it is the right choice for your project needs. Manufacturing plastic or composite parts requires heating and pouring the raw materials into a mold that has been specially made for the part. The four most common molding processes are:

ㆍCompression

ㆍInjection

ㆍTransfer

ㆍExtrusion

Different molding processes are used to create different works. In this article, we will weigh the pros and cons of the injection molding process for thermoset composites.

Advantages of thermoset injection molding

Injection-molded parts may be the most suitable one for several reasons:

ㆍMany different types of materials can be used for injection molding, including thermoplastics and thermosetting resins, polymers, and elastomers. This provides engineers with a lot of control over which hybrid material will produce the best results, especially when it is necessary to meet specific performance requirements.

ㆍVery suitable for high-volume operation.

ㆍPrecision and low waste. Due to the specific mold and material combination, compared with other processes, there is less waste of injection molded parts.

ㆍShort cooling time-the injection molded parts cool quickly, reducing the time required for the injection molded parts to be released from the mold.

 

thermoset injection molding

Thermoset Injection Molding

Disadvantages of thermoset injection molding

For the above reasons, injection molding is an excellent process, but it also has certain limitations and defects. These disadvantages include:

ㆍMold costs – these costs can be very important because precision-made molds are required.

ㆍFlash – Flash is inevitable when injection molding thermoset plastics. Once the part is created and ejected from the mold, the next step is to automatically or manually remove the flash (excess material). Due to the high viscosity of liquid plastics, a flash of thermoplastics is not a problem.

ㆍPart size – The size of the part being created is very important in the molding process. Typically, smaller part sizes (0.1 lb to 6 lb) are injection molded, while larger parts are transfer or compression molded. The number of orders will also determine which molding process is best for the project. Compression molding may be used for smaller parts with a low (or high) volume, while transfer molding may be used for medium to high volume projects. Injection molding will be ideal for large-volume running smaller pieces.

Finally, when choosing a molding process for your part, it is always recommended to talk to a thermoset composite or thermoplastic engineer. After assessing your needs, they will be the most capable and able to make suggestions for your work and provide the highest quality products at the most reasonable cost.

We are a thermoset injection molding supplier. Please feel free to contact us if you are interested in our thermoset injection molding or other products.

Two-Shot Molding vs. Overmolding

Two-Shot Molding vs. Overmolding

Injection molding is a popular manufacturing process, which can quickly produce complex-shaped precise parts without wasting a lot of materials.

Many different processes belong to the category of injection molding, including over-molding and two-shot molding. The two processes are similar, but there are some key differences-here are what engineers and designers need to know:

What is two-shot molding?

 

Two Shot Injection Molds, also known as dual-molds, double-shot molds, or multi-shot molds, are a subcategory of injection molding that allows engineers to create multi-material or multi-colored parts without adding additional assembly steps.

Through the different layers of materials or colors created by the injection molding machine, the two-shot injection molding process is best understood. The first material is injected into the mold to create the substrate, and other materials or materials will be molded around the substrate. After the substrate solidifies and cools, it is transferred by hand, robotic arm, or rotating plane to another cavity of the mold.

From there, the mold opens and rotates 180° with one side of the substrate to meet the other mold chamber and injection molding nozzle. Once the substrate is in place, the second material is injected and combined with the substrate to form a firm hold. Once the second layer has cooled, the last part will be sprayed out.

Engineers should know that Two Shot Mold can be accelerated or slowed down, depending on how the substrate is transferred to another cavity of the mold. Hand and robot arm transfer takes longer than the rotating plane, but the rotating platen molding is more expensive, usually, there are only high-efficiency options, mass production runs.

In addition, it is very important that the material of the mold is easy to bond, and the mold must be aligned to prevent deformation of the parts.

Advantages and disadvantages of two-shot molding

 

Two-shot injection molding is efficient and economical manufacturing technology. This process also produces highly durable terminal parts and assemblies.

From a design point of view, two-shot molding provides designers with a lot of flexibility, because this process can create complex geometric shapes and adapt to multiple colors to produce more beautiful parts.

In addition, because one machine manufactures the entire part, no post-processing is required, and engineers can greatly reduce manufacturing time, thereby reducing costs. However, it is worth noting that the initial two-shot injection molding machine may be costly, and the two-shot injection molding machine is more expensive than the standard injection molding machine. Fortunately, these costs are usually offset by labor savings and assembly costs for large-scale production runs.

What is over-molding?

 

Overmolding, like Two Shot Moulding, is a multi-shot injection molding process that produces a single final product from two or more different thermoplastics. This process is ideal for engineers who want to build components that are powerful, functional, beautiful, and that will not separate over time.

At the beginning of the over-molding process, engineers inject the substrate with a harder over-molding material. Then, the substrate is placed in an over-mold tool or an over-mold cavity within the same mold. The molten-over mold material is then sprayed into, onto, or around the substrate. After the molten material is cooled, the substrate and the over-mold are chemically or mechanically combined. The entire over-molding process only takes 30 seconds.

The product team must remember that all thermoplastics used in the over-molding process must be chemically or thermally compatible with each other. Compatibility with metal substrates is usually not a problem, because they can be used with any plastic over mold, but the product team may encounter compatibility issues when using plastic over molds. If the substrate and mold are not compatible, the final product may be deformed or poorly bound.

However, if two less compatible plastics must be used, the team can design mechanical bonding properties for the part after the fact, although this may result in higher costs.

Advantages and disadvantages of over-molding

 

Overmolding and two-shot injection molding have many of the same advantages. They are ideal for quickly creating durable, reliable, and vibration-resistant parts with complex geometries, but over-molding is best suited for low-volume production runs.

Compared with two-shot molding, over-mold design is also easier, because engineers can use any standard injection molding machine to carry out this process.

In terms of disadvantages, the tolerances of over-molded parts are often lower than those of two-shot injection molding. It is also important to remember that plastic compatibility requirements may constrain designers.

What Materials Are Used for Injection Molding?

In the world of manufacturing, injection molding is a widely utilized process for creating intricate and precise plastic parts. The materials used in injection molding play a crucial role in determining the final quality, strength, and functionality of the produced components. In this article, we will delve into the various materials commonly used for injection molding and explore their unique characteristics. By understanding the different options available, you can make informed decisions when it comes to selecting the most suitable material for your specific manufacturing needs.

1. Thermoplastics

Thermoplastics are the most commonly used materials in injection molding due to their versatility and wide range of properties. These materials have the ability to soften when heated and solidify upon cooling repeatedly, allowing for easy molding and recycling processes. Some of the popular thermoplastics used in injection molding include:

 

Polypropylene (PP)

Polypropylene is a lightweight and flexible thermoplastic that offers excellent chemical resistance, low cost, and high impact strength. It is commonly used in the automotive, packaging, and consumer goods industries.

 

Acrylonitrile Butadiene Styrene (ABS)

ABS is a strong and durable thermoplastic that possesses good impact resistance and dimensional stability. It is often used in the production of electronic enclosures, automotive components, and household appliances.

 

Polycarbonate (PC)

Polycarbonate is a transparent and highly impact-resistant thermoplastic. It is known for its excellent optical clarity, making it suitable for applications such as safety goggles, lenses, and automotive lighting.

 

Polyethylene (PE)

Polyethylene is a versatile thermoplastic that comes in various forms, including high-density polyethylene (HDPE) and low-density polyethylene (LDPE). It offers excellent chemical resistance, electrical insulation properties, and is commonly used in packaging and piping systems.

2. Engineering Plastics

Engineering plastics are a class of materials that exhibit enhanced mechanical, thermal, and chemical properties compared to standard thermoplastics. These materials are specifically designed to withstand demanding environments and provide superior performance. Here are some notable examples:

 

 

Polyamide (PA)

Polyamide, commonly known as nylon, is a strong and lightweight engineering plastic. It possesses excellent tensile strength, abrasion resistance, and is often utilized in applications such as gears, bearings, and structural components.

 

Polycarbonate-ABS (PC-ABS)

PC-ABS is a blend of polycarbonate and ABS, combining the toughness and heat resistance of polycarbonate with the processability and cost-effectiveness of ABS. It finds extensive use in automotive, electronics, and telecommunications industries.

 

Polyether Ether Ketone (PEEK)

PEEK is a high-performance engineering plastic known for its exceptional mechanical, thermal, and chemical resistance properties. It is commonly employed in aerospace, medical, and oil and gas applications where extreme conditions are present.

 

Polyphenylene Sulfide (PPS)

PPS is a high-temperature engineering plastic that offers excellent chemical resistance and dimensional stability at elevated temperatures. It is often used in electrical and electronic components, as well as automotive parts.

3. Elastomers

Elastomers, also known as rubber-like materials, are characterized by their elasticity and flexibility. They are commonly utilized when parts require excellent sealing, cushioning, or shock-absorbing properties. Let’s explore a few examples:

 

Thermoplastic Elastomers (TPE)

TPEs are a versatile group of elastomers that combine the processing advantages of thermoplastics with the elasticity and softness of traditional rubber. They find extensive use in the automotive industry, medical devices, and consumer products.

 

Silicone

Silicone elastomers are known for their high-temperature resistance, low toxicity, and excellent electrical insulation properties. They are widely used in the medical and food industries, as well as for seals, gaskets, and electronic components.

Conclusion

In summary, the materials used for injection molding are diverse and tailored to meet specific requirements in terms of strength, flexibility, chemical resistance, and more. This article provided an overview of various materials, including thermoplastics like polypropylene, ABS, polycarbonate, and polyethylene, as well as engineering plastics such as polyamide, PC-ABS, PEEK, and PPS. Additionally, elastomers like TPEs and silicone were also discussed. By understanding the unique properties of these materials, you can make informed decisions and select the most suitable option for your injection molding needs.

 

Remember, choosing the right material is crucial in achieving high-quality and cost-effective production. Always consult with experts in the field to ensure the optimal selection of materials for your specific application. WIT MOLD can meet the demand for plastic products that are reasonably priced, durable, and require precise specifications every time. We are your one-stop supplier of high-quality, cost-competitive domestic molded plastic products using various plastic materials.

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