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In plastic injection molding, the process of demolding a part is as important as creating the mold design and forming the part. Successful demolding is essential for maintaining part quality, reducing mold damage and minimizing cycle times. To optimize the process, here are three crucial tricks to enable a clean release from the mold without creating defects in the part. These recommendations will generate more consistent and efficient demolding.
Injection molding creates complex plastic parts with high precision and repeatability. However, like any manufacturing process, it comes with its challenges, including defects in the molded part. One of the most common defects is sink marks. These small surface depressions can compromise not only the aesthetic appeal of a product but also its functionality. This blog will describe sink marks, explain what causes them to occur and offer methods to prevent these defects.
Cooling the molten plastic injected into the mold in a plastic injection molding machine is a critical process. The cooling system controls the temperature of the mold and impacts the quality and forming efficiency of the injection molded product. Uneven temperatures in the mold create temperature differentials in different sections of the product. The varying temperature across the product can cause temperature-induced stress, shrinkage, warping and deformation. Products with complex shapes and uneven wall thickness are particularly susceptible to these effects if the temperature distribution is uneven. An efficient cooling system that can maintain a uniform temperature distribution can minimize these defects in the molded parts. This article will present both options and recommendations for designing effective cooling channels in injection molds and explore strategies and considerations crucial for maximizing cooling efficiency and optimizing molding outcomes.
A minimally invasive medical procedure or device simplifies traditional treatment methods, causing the patient less pain and reducing the risk of complications. When Trice Medical was experiencing unnecessary complications and frustrations obtaining critical injection molded components for its manufactured equipment, it realized the need for a new business partner that could supply a reliable, painless solution. Recently, President of Trice Medical, Mike Steen, sat down to discuss his company's long-standing partnership with AIM Processing. With more than 15 years of experience in the industry, Mike shared valuable insights into the strong collaboration between the two companies, the value AIM Processing brings to the table and how their partnership has evolved over time.
Maintaining proper wall thickness is one of the most important aspects of designing custom injection molded parts. Overly thick walls not only waste material, they’re also more likely to exhibit part defects such as sink marks. On the other hand, overly thin walls are prone to warping and cracking, while also generally lacking the strength necessary for a durable end product.
In the plastics manufacturing industry today, automation is the name of the game if you want to be competitive. Automated injection molding machines, robotic part handlers, automatic loading/unloading systems… In fact, automated manufacturing technology has become increasingly common throughout the American manufacturing sector as a whole. Essentially, these newer technologies help US manufacturersoperate as lean, efficient and productive as possible, thus meeting the new demands of onshoring while remaining cost competitive to the global marketplace.
Many factors go into determining the overall cost of producing your custom injection molded parts. First there’s the product design, development, and iterative prototyping process if required. Once your design is finalized, next up is the tooling cost to build your mold that will be used to make your product. Even once manufacturing is underway, a number of factors will still dramatically affect your ongoing production costs: material type, material usage, and machine cycle time to name a few.
Today’s complex injection molded parts often require more complicated designs with more contours and more walls throughout. This can complicate fill patterns, cause unexpected voids/gas traps, and introduce warp. As a result, it has become increasingly critical to ensure uniformity so that the end products offer the expected strength and performance they are designed for. That’s where mold flow analysis comes in.
Embarking on a new custom injection molding project can be intimidating, especially for customers who are new to the industry. If you’ve never seen the process through from start to finish, it can seem extremely complex and even overwhelming with all of the details you’re expected to bring to the table.
Today’s advanced injection molding techniques take an intelligent, disciplined approach to the manufacturing process that ensures both higher precision and efficiency. Making the right choice between hot runner manifold systems and conventional cold runners is just one of the many considerations we make. Nevertheless, it’s one of the most critical decisions in order to optimize our injection molding methods for your unique products and volume requirements.
