If you’re looking to set up your injection molding machine or take on a new job that includes injection molding maintenance, then you’ve come to the right place. In this ultimate guide, we’ll cover everything you need to know about injection molding machines, from setup and maintenance to how they work and what the process looks like.
We’ll also touch on some of the most common terms associated with injection molding and key considerations forcing the right machine for your needs.
What Is Injection Molding?
You’ve probably come across injection molding in your fair share of products, but you may need to learn exactly what it means. Put injection molding is a manufacturing process used to create parts and components from thermoplastic and thermosetting plastic materials.
It works by injecting a melted material usually a plastic polymer into a custom made mold in the desired shape. The material then cools and solidifies in a mold, producing the finished product.
Uses of Injection molding
Injection molding is widely used for making high-quality medical components, automotive parts, and other items. It’s especially effective for mass-producing details with intricate shapes that would otherwise be difficult to make using different methods.
Injection molding machine can produce high volumes of identical products with minimal waste, making them cost and time efficient in many cases.
Injection Molding Machine Setup
If the setup process can be daunting if you’re new to working with injection molding machines, don’t worry, we’ve got you covered! Here are some of the essential steps in setting up your injection molding machine:
Check Safety Features: The most important thing you should do is inspect the safety features of your machine. Ensure that all guards, sensors, and emergency interrupt buttons are properly functioning, and replace anything that looks damaged.
Set Tooling Parameters: You’ll need to set the parameters to ensure your tooling is firmly secured before starting. This includes verifying clamp force settings and ensuring temperatures are optimal for a successful injection cycle.
Adjust the shape height and pressure settings: Once the parameters are set, the mold height and pressure settings should be adjusted to ensure that the plastic fills and cools uniformly.
Monitoring of cycle time and status display: Finally, monitor cycle time, pressure gauges and temperature gauges during each cycle run to ensure everything is running smoothly and efficiently.
Types of Injection Molding Machines
Now that you know the basics of injection molding, let’s review the different types of machines used in the process. Your choice of device depends on the type of product you’re making, so it’s important to understand their capabilities.
Hydraulic Injection Molding Machine
The most common injection molding machine is a hydraulic injection molding machine. This type of machine pushes heated plastic through a plunger, which injects it into a mold cavity to be cooled and released as a finished product.
Electric Injection Molding Machine
An electric injection molding machine may be more suitable for smaller and lighter parts than a hydraulic one. Electric devices use less energy and are faster than hydraulic ones, plus they offer more repeatable accuracy since they tend to be more sensitive than hydraulic ones.
Toggle Clamp Injection Molding Machine
Finally, you have toggle clamp injection molding machines. These machines have higher speeds than electric or hydraulic ones but require more maintenance due to their complicated operation mechanics. They are usually used for high-quantity production since they can produce larger quantities with fewer labor costs than other types of machines.
How to Select the Right Injection Molding Machine
Choosing the right injection molding machine can be a complicated proposition, and finding the one that best meets your needs requires taking a closer look at the specific requirements of your application. Some key factors you should consider when making your selection:
Price
When it comes to cost, it’s important to remember that you want to maintain quality for cost-efficiency. Injection molding machines come in various price points. However, buy something that will last and is built with good-quality materials and components.
Type & Size
Injection molding machines are classified according to their type and size. The kind of machine refers to a particular chamber configuration (including clamping, injection, and mold functions). The size of a device is usually determined by its shot size in ounces or grams of plastic material per cycle.
Clamping Mechanism
The type of clamping mechanism used in an injection molding machine determines how much force can be applied during each cycle of operation. It’s important to select the right clamping type for your application, or you could wind up with poor part quality or damage to the machine itself.
Maintenance & Serviceability
Another factor to consider is how easy it is to maintain an injection molding machine once you have purchased it. Look for devices with accessible mounting points and removable covers that make maintenance easier and less time-consuming.
You should also ensure the vendor offers reliable service and support after purchase to resolve any technical issues quickly.
