Plastic is a primary material used in most industrial and consumer products. Manufacturing plastic components require precision accuracy and a method to produce large volumes of identical and different part components. Injection molding is a popular plastic manufacturing process that is most commonly used in producing consumer products. We are a leading injection mold manufacturer in India with high-quality precision components for a wide variety of purposes. We cater to any type of industrial and consumer products. There are three significant phases of injection molding. They are product design, mold design and production. Each stage has its set of processes and classifications that differentiates the type of product manufactured.
The final product can never be accurate without a proper design process. It is a crucial phase in the production process. The design process will allow you to prevent costly mistakes in the final production phase. The design process aims at bringing out the function of the component and the manufacturability. You can arrive at the aesthetics of the product and decide on the assembly. The objective of the design phase is to be able to meet the required production without any issues.
Product design is accomplished using applications like SolidWorks and computer-aided design. Proficiency is required in using these applications to create more accurate prototypes and quicker iterations. One way to avoid expensive mistakes is to plan for uniform thickness, which can be gradually changed when it is entirely unavoidable. The design phase will eliminate building stress in the products. The design phase will have the active involvement of design engineers who will discuss, design and improvise ideas per client expectations. We have a team of design experts who are adept at deciding simple solutions for complex products.
After the design is tested and approved for further production, we will design the process's mould. A mild is made from hardened steel, aluminium, pre-hardened steel or beryllium-copper alloy. Hardened steel is the most expensive one, but it lasts long. When you want to produce a large volume of products, hardened steel is the right choice. Pre-hardened steel is less expensive but does not last as long as hardened steel. Aluminium is most commonly used for single cavity prototype tooling. It is mainly used for lower quantities of production. Once the prototype mold from this tool is tested and approved, a multi-cavity production tool will be produced.
Beryllium copper alloy is used in parts where we require quick heat removal or concentration of shear heat. The mold designing phase is another opportunity to avoid costly defects. A poor mold with an improper draft and gates will be an expensive mistake. The draft is the angle from which part ejects. An insufficient draft can cause ejection issues that cost money and time. Improperly sized gates will cause a scar in the product. The volume of components and the material used will also influence the decision making on the type of mold to use.
The actual manufacturing will start once the product design and mold design is approved. In the injection molding process, we can use thermoset or thermoplastic materials in their granular form. The plastic will be treated to a predetermined temperature-driven through the gates to reach the mold. The mold will be filled with molten plastic, and appropriate pressure should be applied for a specific duration. The mold will be cooled for a predetermined time and after which the screw will be withdrawn. We will open the mold and eject the part. The gates will have to be removed manually, or they will automatically shear off. We can repeat this cycle to create multiple parts in a relatively shorter duration. We can create functional, efficient and aesthetic designs that are ready for production. It is the best way to produce plastic components that are required in large quantities.