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What Is Injection Molding And Why It Is Important

2013-12-31T09:33:11+00:00

What is Injection Molding?

Injection molding is a manufacturing process widely used for the production of articles of plastic toys and trinkets for automotive body panels, water bottles and cell phone cases. A liquid plastic is forced into a mold and cured - it sounds simple, but it is a complex process. The fluid used will vary from hot glass to a variety of plastics - thermosetting and thermoplastic.

History

The first injection molding machine was patented in 1872, and celluloid was used to produce simple everyday items like hair combs. Just after World War II, an improved injection molding process much - ' screw injection ' was developed and is the most used technique today. Its inventor James Watson Hendry, later developed ' blow ' which is used for example to produce modern plastic bottles.

Types of plastic

The plastics used in the injection molding are polymers - Chemistry - either thermosetting or thermoplastic. Thermosets are set by the application of heat or through a catalytic reaction. Once cured, they cannot be re-melted and reused - the curing process is chemically irreversible. Thermoplastics, however, can be heated, melted and re-used.

The thermosetting plastics include epoxy, polyester and phenolic resins, while thermoplastics include nylon and polyethylene. There are almost twenty thousand compounds available for plastic injection molding, which means that it is not a perfect solution for almost any requirement molding.

Glass is not a polymer, so that does not conform to the accepted definition of thermoplastic - even though it can be melted and recycled.

The Mold

The mold manufacturing has historically been a highly skilled art ( "die - making" ) . A mold is usually in two main sets fastened together in a press. Make a mold often requires a complex design, multi-function machine and a high degree of skill. The tool is generally of steel or beryllium copper, which is used for the manufacture of the mold requires a heat treatment to harden it. Aluminum is cheaper and easier to machine, and can be used for the production of the shorter term. Today, milling techniques discharge machining ( " EDM " ) enabled computer control a high degree of automation of the process of mold manufacture.

Some molds are designed to produce several related parties - for example, a model airplane kit - and these are known as family molds. Other mold designs can have multiple copies ( ' impressions ' ) of the same article produced in a ' shot' - that is, one injection of plastic into the mold.

How Injection Molding Works

There are three main units make up an injection molding machine - the feed hopper, barrel heater and the ram. The plastic in the hopper is in granular or powder form, although some materials, such as silicone rubber may be a liquid and may not require heating.

Once hot liquid, the ram ( ' screw ' ) causes the liquid in the mold and the liquid held firmly sets. More viscous molten plastic required higher (and higher loads press ) pressure to force the plastic in every nook and cranny. The plastic mold is cooled as the metal conducts heat and then the press is cycled to remove the trim. However, for thermosetting plastics, the mold is heated to secure the plastic.

Advantages of Injection Molding

Injection molding allows complex shapes to be manufactured, some of which could be almost impossible to produce economically by other means.

The wide range of materials allows almost exact coincidence of the physical properties required by the article, and multilayer molded allows the adaptation of the mechanical properties and visual appeal - even a toothbrush.

In volume, this is a low-cost process, arguably, with minimal environmental impact. There is little scrap created in this process, and waste that is produced, and to be re- ground and reused.

Disadvantages of Injection Molding

Investing in tools - make the mold - usually requires large production volumes to recover the investment, although this depends on a particular object.

The output of the tool takes development time, and some parts do not easily lend themselves to a practical design mold.

The Economics of injection molding

A mold of high quality, although relatively high cost, will be able to produce hundreds of thousands of "impressions." .

The plastic itself is pretty cheap, and despite the energy required to heat the plastic and press cycle (to remove each print ) the process can be economical, even for the most basic products, such as bottle caps.

With several hundred new plastic compounds being developed every year, and techniques of modern molds, injection molding is safe to continue increasing use in the next fifty years. Although thermosets cannot be recycled, its use, especially for high-precision components, is also destined to grow.

How to choose a good plastic injection mould Maker

2013-12-26T14:24:13+00:00

At the heart of any injection molding operation is the plastic injection mould. A good mould manufacturer will produce quality parts.

As an injection molder, one of your priorities should be to find a mould maker who actually wants to make a difference to your productivity.

There are several advantages to this:

Lower costs
Fewer rejections
Faster cycle times
Ability to meet deadline
Better working relationships
Higher morale among employees

When acquiring a manufacturer of plastic injection moulds there are a number of things to consider.

The Right Approach

Being a manufacturer of plastic injection moulds today means more than cutting steel.

A manufacturer of plastic moulds should keep your customer injection molding since the beginning of a new concept right through the mass production of parts especially when it comes to reducing cycle times by using moulds aluminum.

The mould maker should know what questions to ask and be aware of the problems of design pieces that could make difficult molding and mould construction.

Changes made in the early stages could save thousands of dollars in shaping waste regarding denials and slow cycle times.

This means that the molder can make more money, get the jobs completed before and will not suffer the stress and headaches associated with making poor decisions that often occurs at the start of a product development cycle.

The plastic mould manufacturer must also be present during commissioning mould. Very often the new moulds have not been tested in a production environment and usually have some minor problems that relate to the manufacture of the mould. The mould maker has to see the effect on production and discuss with molding the best way to fix it.

Another reason why a mould maker must be present during commissioning is to ensure water circuits are connected correctly. Water circuits should not be repeated, as this can cause problems with part quality, as deformation.

Having a mold maker with the right approach is vital when molds are made with tight tolerances such as moulds. The stack mold maker must be able to communicate the benefits of stack moulds and dispel misconceptions.

What's more, if you are thinking of buying plastic injection molds used, then a good mold maker must also be able to advise you on the current condition before purchase. Molds used often need repair work in order to produce quality parts. Thus, the potential costs of repair are known before buying.

How a mold maker plastic injection works to get the right approach?

Start by taking the time to learn about transformation and understanding the everyday problems faced by molders, problems such as hot runner mold. When these problems are included by the manufacturer of molds that naturally look out for potential problems arising from poor casting part and mold design before cutting steel.

This can only strengthen the relationship and communicate the commitment to project success molding.

Prices

Pricing mold is usually the first test in a new project and for good reason. The lower the price the faster the recovery period which means you can start making a profit before.

However, be careful as there are hidden costs associated with buying a cheap injection mold - especially from low-cost countries ( LCC).

The price of the molds Lacks can be up to lower the molds manufactured in Western countries like Australia 70 %.

Initially this may seem very attractive, but the real cost should be calculated over a period of time, in which case you're likely to find that there was no saving.

In fact, it will probably cost money, because of quality problems and the ongoing slow cycle time.

A common story in Australia is where injection molders buy new molds cost of a CDL just to find one or more of the following:

Slow cycle time
Poor quality part
Constant production interruptions due to difficulties ejection

These issues require constant attention so any cost savings in the initial purchase price are quickly eliminated.

So in the end you get what you pay for.

There are many good manufacturers of plastic injection molds in Lacks, just make sure you spend time to find the right one for you.

Balance between price and quality. Do your research and pay a little more to get a mold that will produce plastic parts of consistent quality.

Delivery

The delivery is critical to get parts to market on time. When the mold is delivered on time the molder can start making money and meet the production needs of the customer.

No associated with delays in delivery pressure, because there are no customers the parts you have no more demanding.

A good manufacturer of plastic injection molds will be able to meet all deadlines , regardless of your workload if you have the leadership and proper management.

Mold reliability

If a mold maker can build a template with the right materials, heat treatment, corrosion protection and machining tolerances then everything will run smoothly during its intended life, provided it is properly maintained.

The mold should produce quality parts correct cycle time without interruptions due to the difficulty of removal.

There should be no need for a shaping of spending time, energy and money troubleshooting and repair of a mold. Employees must be free to work on tasks that make major money.

Manufacturing techniques of design parts, equipment selection part, mold design, mold processing and should all be taken into account when making a mold that is reliable.

That is why constant communication between molder and mold maker is essential for success.

mould making and molding in retrospect 2013

2013-12-24T09:08:32+00:00

Looking back in 2013, was a very good year for most mould makers and molders. Most companies were busy - especially those that serve the automotive industry, where the demand is for suppliers to increase capacity. While some of the largest Tier 1 company is meeting, there is a reluctance among smaller suppliers, level 2 to invest in expansion. They have been down this road before.

As noted in several different blogs on this topic, automakers, in particular, have " begun to insist that suppliers locate their U.S. operations as close to the final assembly as possible. " Obviously, this will mitigate the risk of supply chain and make it easier and less costly for OEMs life.

At the same time, it was noted in another blog that a number of OEMs - not just automotive companies that are known for bad payment terms - are you extending payment periods over improve its capital position work by releasing cash. Of course, what is good for OEMs often is bad for providers? The key for providers is " just say no" to offers that promise to hurt their bottom line. Maybe in 2014 we will see more molders, and mold makers are adamant.

A story that has a lot of attention - and generated some email in my inbox was iMFLUX history. iMFLUX is a subsidiary of Procter & Gamble that is being established in a newly leased 317,000 -sf vacant industrial building in Hamilton, OH, where eventually 200 workers are employed to develop new plastics processing technology (low temperature, molding low pressure ) and more likely to build tools that are not smooth cooling channels, which P & G believes will save the company $ 150 million in packaging costs ( packaging required thinner walls -) and reduce cost's capital (cost of mold) for $ 50 million.

We might discover if this experiment in 2014 to build their own tool and make your own molding actually save the company money, but the actual providers of the company could receive a nasty surprise. However, given that P & G is one of the OEMs announcing the laying of payments to suppliers, P & G could be doing a favor.

Great stories in 2013 had to do with 3D printing, additive manufacturing known as. You cannot help but notice that almost all publications of manufacture - from major news media for most B2B publications - carried stories about 3D printing almost every day. The 3D plastic gun has a lot of attention - especially from the federal government. From big companies like 3D, Systems and Stratasys that develop and manufacture equipment and materials for industrial sized entrepreneurs who are all trying to get Kickstarter funding for the next desktop printer for the tinkerer, 3D is the "big deal" .

New materials are making it possible to print everything from ears and knee joint for aircraft parts, automotive components, and yes, even the molds (cores and cavities ) .

Perhaps history additive manufacturing was the largest and most interesting for the year. From my point of view, seems to be a disruptive technology for both molders and mold makers, and although we have not seen all the implications of 3D technology at the moment - see the horizon! It might be a little beyond somewhere in 2014.

Auto supplier boosts automotive bio-plastics

2013-12-23T10:17:12+00:00

Auto supplier Faurecia SA has launched the production of injection molding bio-compound that combines hemp and polypropylene in Europe, and is looking for opportunities to expand the technology to North America.

At the same time, the company is developing a completely natural compound that combines natural fillings with an herbal resin.

Both developments come as the automotive industry is to reduce weight and lower price fluctuations that come from more traditional materials.

"It's only two product cycles now until we get to that ( 54.5 miles per U.S. gallon fuel economy ) standard in 2025," said Jay Hutchins, director of marketing and product planning for Faurecia North America during a telephone interview on Dec. 12.

Faurecia showed a range of natural materials during the Los Angeles Auto Show in November, and displays them in an event during the press preview at the North American International Auto Show in Detroit in 13-16.

Compounds with renewable materials as a replacement for glass or talc auto parts are not new. They have been in production for over a decade, but is normally used in compression -molded parts.

NafiLean Faurecia is an injection molding material, which can be used in existing equipment, reducing the costs of bringing it to market.

The company began manufacturing door panel substrates with him during the summer two piece PSA Peugeot Citroën Peugeot 308.

"We've been doing compression molding for 25 years and with the natural fiber for 10 or 15 years," Hutchins said. "These are great products for something with a relatively flat geometry without undercuts. When talking off the top of the door, there are a lot of constrained geometry ".

Hemp also offers an enhanced level let alone on glass density, so Faurecia can produce a piece of thinner walls, with the same structural capabilities. In the case of the 308, which is saving 400 grams per door panel said.

Faurecia continues to prove NafiLean prospects elsewhere, especially the instrument panels, and is looking forward to starting production in the U.S. is lining material's suppliers, as well as sources for hemp.

In tests, hemp has been the best natural material for bio- composites because it works better with the chemistry of PP, despite U.S. laws that restrict hemp production in the country. Other companies have from Canadian hemp farmer's compression molded parts.

The next step beyond NafiLean be based material of all bio - Hutchins said. Faurecia has collaborated with Mitsubishi Chemicals and other partners to develop BioMat that combines natural fillings with a bio -based resin.

" The next step in the evolution is BioMat " he said. "The idea is 100 percent green content. You could be isolated from the fluctuations on the oil market that affect resin prices now."

Faurecia expects the Biomat injection molding could do in cars in 2016.

For the plastics industry in China, the slowdown may be over, but the rebound is not in sight

2013-12-18T09:47:30+00:00

If an optimist sees a glass half full and a pessimist sees it half empty , what do you call someone who can not decide what they see ?

You can call a business of trying to decipher the plastics manufacturing environment in China today.

Reports late November and plastics companies traded analysts pointed to a "shameful " and " uncertain " picture , with suggestions the worst may be over slowing this year, but without solid offensive view.

For example, China 's second largest manufacturer of plastic machinery , Chen Hsong Holdings, said on November 27 that sales in the country increased only 4% for the six months ended 30 September.

Easier credit in China in recent months did bring a small recovery , but the company said the plastics factories remained cautious investment and looking to the government for the signals.

" A tight monetary policy adopted by the new central government of China - crucial for long-term economic stability - will inevitably lead to short-term pain ," said company based in Hong Kong. "The market in China during the second half of this financial year continued to be veiled in uncertainty, depends largely on the direction and degree of tightening credit policy of the Central Government . "

Injection molding company of Hong Kong Karrie International Holdings half year saw sales fall 21% in the plastics molding and metal parts division , which led the company said in its earnings report November 28 I was coming up investment in robots and automation.

And the plastic toy maker Lung Cheong International Holdings said on November 28 that sales of half a year fell 19 %, which is attributed to the economic problems worldwide .

It was not all bad news. Others reported better results.

L. K. smaller rival Chen Hsong Technology Holdings said sales in the division of plastic machinery rose 13 % on strong demand in China, and the dye and plastic mixer engineering Ngai Hing Hong said that healthy sales in China were main engine that drives revenue by 14%

to a record HK $ 1.86bn ( € 177m ) in the year ending June 30.

Ngai Hing Hong But just held , making a cautious tone about the future amid challenges in China and Europe.

"With the eurozone crisis unresolved ... and the ongoing slowdown in economic growth in China , the group will continue facing the challenges in the second half of 2013," he said.

"However , the recovery of the U.S. economy has helped stabilize exports to China , which management believes will present opportunities for the world market and the price of raw materials should be stable. "

Examining China 's manufacturing industries on an analysis of 27 November the Manufacturers Alliance U.S. based for Productivity and Innovation said the picture was "shameful" .

" While recent Chinese data have suggested a bottoming of the sharp slowdown in Asia 's largest economy , there is a definite sense of recovery in the near-term horizon ," according to MAPI. "Economic growth stabilized in the third quarter primarily due to a gradual recovery in exports and public investment . "

MAPI predicted that production in China could see a moderately slower growth this year of 9.2 % to 9% in 2014 as global GDP growth fell from 7.3 % this year to 7 , 1% by 2014.

Major trade group Plastics country , the Association of Plastics Processing Industry of China, estimated in early November that the industry grew by 5 % in the first nine months of the year , a significant slowdown from double-digit increases in years.

" Such a muted forecast likely portends a prolonged period of slower growth as the country faces a sluggish world economy, increasingly difficult demographic challenges affecting the supply of labor " and the need to rebalance its economy towards consumption domestic private, MAPI said.

Still, plastics companies reporting financial results continued investments in new capacity, and seeking long-term opportunities . And even with the slowdown , the growth of the plastics industry in China still larger than other major economies of the world plastics .

LK was building a new production base in Zhongshan , Guangdong Province . Ngai Hing Hong said it will continue expanding its sales network in mainland China, where significant resources are focused in recent years , and said he expected to benefit from increased Chinese exports and a gradual recovery in the U.S. economy .

And Hsong Chen said he had nearly completed a previously announced expansion space 88,000 m² factory in Shenzhen , to give more capacity in ultra - large tonnage presses and help them achieve what he called a leadership position in this sector.

He said he planned to submit an injection molding machine of 6,500 tons , the largest yet made in Asia , to a customer in early 2014 .

International sales of Chen Hsong also suffered in the period. He said he saw encouraging signs of their efforts to grow in markets such as Brazil and Europe, but noted that overall international sales still fell by 7 % in the first half due to the depreciation of currencies quickly in some major developing economies .

New Southeast Asian currencies in the broader market fell by 10% against the U.S. dollar in the period, the company said . But let Chen Hsong suggesting the status quo would not be so bad.

" The group is of the opinion that the GDP of China should maintain its current growth rate of 7.8 % and that, barring unforeseen circumstances , we expect stability in the business development group can be guaranteed ," said the company.

Two keys to a successful business: Training and Retenting of employees

2013-12-17T08:25:42+00:00

Plastics processors and mold makers are complaining at the lack of skilled workers. That not only concerned about these companies, but is a concern for their customers as well. The automobile industry, for example, expressed through a series of surveys lately that the lack of engineering and other skilled personnel is an important compliance requirement increasing production challenge.

The results of the November survey original equipment Suppliers Association, revealed that there are three areas where auto suppliers are having a hard time filling position: engineers, technicians and skilled trades per hour The OESA survey noted that companies were having more difficulty recruiting qualified candidates available and orders for these employees are open longer.

For engineering positions, the three main areas are general engineers, product engineers and manufacturing engineers. In fact, engineering positions are taking the time to fill executive positions as high - an average of four months, the report said. Tooling Engineers also was listed as a hard position to fill. The skilled trades OESA survey reported as difficult to fill that includes tool and die makers, maintenance tools and machinists and tool.

With so many companies looking for the same types of employees, the competitions for these positions are even more difficult to cover. That is leading many companies to start their efforts at vocational school and middle school one respondent to the survey OESA said: " The awareness of manufacturing jobs available to the college, high school, and levels of joint vocational school, " as a key to solve the problem. "We are taking our schools needs within the community. "

Another key is to find ways to retain these employees once found and hired. Continuous education and skills is the key to this. Tata Technologies, an outsourcing of engineering services and product development IT services provider to the global manufacturing industry, with North American headquarters in Novi, MI, recently announced the addition to a series of training courses for plastics for the Routsis its program of engineering professionals .

The use of plastics in manufacturing is increasingly important as product development across the industry segments increasingly demanding viable alternative materials that are durable and lightweight . In the automotive industry , earlier this year, the National Academy of Research of the National Science Council (NRC ) published a report indicating that light plastics and plastic composites are essential to help automakers meet stricter CAFE standards 54.5 miles per gallon by 2025. Support this report, industry representatives stressed plastics and plastic composites plastics can significantly reduce the load of the engine of a vehicle, which increases mileage and reduces emissions of greenhouse gases, said Tata Technologies.

In general, the plastics industry is the third largest segment in the U.S. manufacturing, A growth of 2.3 % annually since 1980, compared with 1.9 % per annum growth for manufacturing as a whole during the same period, according to the Society of the Plastics Industry.

When plastics processors and mold makers to find and hire good people, continuing education programs is one of the keys to employee retention. No matter what the service industry, you need to ensure your customers that you can keep up with your requirements with the best possible staff. People make the difference to your success and that of its customers.

TMT China buy ZF's Rubber & Plastics Unit

2013-12-16T11:10:03+00:00

SHANGHAI - Zhuzhou Times New Material Technology Co. Ltd. signed an agreement with ZF Friedrichshafen AG to acquire its business unit Rubber and Plastics . Transaction is expected to close in the first half of 2014 and is subject to regulatory approvals in China , Europe and the shareholders of TMT .

Financial terms of the deal were not disclosed. TMT said operational headquarters of the business unit will remain in Damme , Germany, and all employees will be retained .

"Solid Future investment support for our activities TMT Rubber & Plastics certainly gives us greater opportunities for global business development ," said Torsten Bremer , head of R & P business unit of ZF .

Rubber & Plastics business unit of ZF generated approximately $ 962.7 million in sales with about 3,300 employees in nine locations in Europe , North America, South America, Asia and Australia .

ZF CEO Stefan Sommer said TMT offers opportunities to drive business your company could not have provided . The company is " delighted that we have found a strategic partner following a long-term strategy , it is willing to invest in the business and provides the best possible solution for our employees and customers," said the executive.

TMT is a leading component of noise , vibration and harshness and polymer composites for railway, wind power industry and the automotive supplier. TMT said it aims to expand in the global automotive market noise , vibration and harshness to make Rubber & Plastics business unit of ZF one of its main business units and their primary automotive platform globally.

" The management team and employees of the business unit , rubber and plastics have done an outstanding job in the past and are looking forward to further developing the business Rubber & Plastics, along with them, " said the CEO of TMT Jun Yang .

Automobile industry concerned about mould manufacturers ability to fulfill the demand for tools

2013-12-16T00:00:00+00:00

Concerns abound in the automotive industry over whether mold manufacturers can keep up with release dates scheduled for 2014 vehicles. With the number of vehicles expected to exceed 17 million in 2014 and rising again in 2015, suppliers of OEM and Tier 1 are in doubt about the ability of the mold industry .

A report released on October 31 through the port of Results Inc. in cooperation with the Association Original Equipment Suppliers (HRI 2013 Vendor Tooling Study) , said that in about five years, the required capacity of the supplier mould making industry will to $ 15.2 billion , with available power supply of only $ 9.25 billion . With tools a critical component of the supply chain , representing an average of $ 550 per vehicle in North America in 2012, the volume of the vehicle, this capacity problem affects the entire value chain, according to the report .

"Capacity will become a serious challenge for the automotive industry in the near future . If the mold tooling industry in North America does not respond to the challenge of someone, like tools vendors from Europe and Asia, will be ," said Laurie Harbour, president and CEO of Harbour Results Inc.

One of the key strategies identified in the survey results to resolve port impending capacity problems include early collaboration - as early as 36 months before the release of vehicles - including OEMs , Tier 1 and tool vendors . "Increased collaboration leads to improved manufacturability , increased input in the design phase , a better understanding of the capacities of suppliers and more ," said the report.

Other strategies include a focus on the price (compared to price ) and the management of the value chain . " Today, the industry is focused on increasing the pressure on prices and the price of the tools , rather than the cost created along the entire value chain of tools," the report said. " OEMs are using a number of different tactics to lower the price of the tools and services , including the adjustment of the terms of payment and supply of low-cost country . "

"The search for lower prices , especially in low-cost countries is not the answer," Harbour said. "The gap ahead for countries like China has declined and continue to decline . China remains an option for the moulds and tools, but highly complex , critical tools will stay here . If the focus does not shift to the management of costs, incredible challenges as industry capacity grows in this region " will face .

Toolmakers Need Skilled Workforce

2013-12-12T00:00:00+00:00

The North American tooling sector is looking both strong and lean these days. That's good news. Mold makers were rocked during the Great Recession, especially those that relied on the automotive industry. And that's a huge market for North American toolmakers — 89 of the 112 companies in our Oct. 7 ranking make automotive tools.

There was some consolidation in 2009, and then a rapid recovery. According to a soon-to-be-released study from consulting group Harbour Results Inc., the tooling sector has been growing rapidly for the past three years, and now capacity is starting to get tight.

Laurie Harbour, the firm's president and CEO, says the next steps for tooling firms will be critical.

"There's no doubt that the pressure is still there on tool suppliers to continue to reduce lead time and price," she told PN's Rhoda Miel.

The plastics industry knows how to deal with pressure to keep costs down — make investments that improve efficiency. Successful toolmakers will invest in automation to help them compete globally.

And let's not forget about the human element — skilled workers. Shops can have all the best equipment in the world, but if they don't have trained employees they're dead in the water.

Mold makers have been talking about a shortage of skilled workers for decades. But the situation is just getting worse.

Tooling company owners shouldn't expect someone to solve that problem for them. The labor shortage is a cultural problem. Parents aren't pushing bright children into the manufacturing trades these days. The consensus is that there's no future there. And who can blame them, with stories of manufacturing plant shutdowns and stiff competition from China so fresh in their minds?

But the truth is that North American manufacturing is globally competitive. And skilled labor is a critically important part of the equation. Toolmakers, more than most manufacturers, need to take an active role in training the next generation of manufacturing workers.

But remember, it all starts with changing public attitudes about manufacturing. That will go a long way toward helping companies recruit — and retain — bright workers.