Plastic manufacturing is a primary industrial sector in India. Injection moulding is an important process for manufacturing plastic products. It is a process that helps in fast production of identical products in large quantities. This can be disposable consumer goods or high precision engineering components. We are leading injection moulding manufacturers in India who produces quality plastic materials for industrial purposes as well as consumer goods. Even thermoplastics can be processed using injection moulding. The materials most commonly used in this process are nylon, polycarbonate, polypropylene, acrylonitrile butadiene styrene.
The process of injection moulding accounts for a significant portion of all plastic products produced in India. Almost all industrial sectors use parts and components that are injection moulded. It can be car bumpers, wheelie bins and other large and micro components. The process enables us to produce thousands or even millions of times the same parts or components. It is one of the most efficient and popular manufacturing processes that help in the production of plastic articles in large numbers almost every day.
We engage with our customers in India to understand their requirements so we can design them accurately. There are many standard and identical items like the regular household components and precision engineering components required and these can be manufactured in large quantities in a short time with high quality. The plastic articles come in a variety of sizes, shapes, strength and other types of thermoplastic that can be effectively manufactured using injection moulding. Creating a mould is the first step in this process. The mould will hold the liquid plastic into the required shape. Advanced technology like computer-aided design is used to create the design digitally. This is called prototyping. We must get the prototype validated by the customer before we create the mould.
An industrial designer or an engineer helps design the prototype and manufacture the mould. A mould or a toolmaker is used to produce the perfect mould. 3D Printing is also used to create mould. If the required plastic article is fairly simple, the mould itself can be printed to create more parts. The moulds created using 3D printing is not as durable as the moulds made out of aluminium and steel. A 3D printed mould can only last for around hundreds of cycles whereas metallic moulds can handle thousands and millions of cycles. The 3D printing process creates a layered surface and hence the products will not have a smooth finish compared to the metal counterparts. Based on the product and quantity required, we must select the type of mould.
The mould has to be thoroughly tested before we move it to the production line. The plastic granules are filled into a heated barrel where it is melted into a liquid. This liquid is passed through the injection moulding machine and into the mould. The liquid plastic will form the shape of the mould. The moulded plastic will cool and become solid within a few seconds. The newly formed plastic article is then ejected out of the mould. This process is repeated to manufacture millions of identical plastic components.
The main advantage of the injection moulding process is its ability for large scale production. Though the initial cost for designing and making mould will be high, the subsequent process of producing each unit of the plastic article is pretty low. Injection moulding produces very low scraps compared to traditional methods. 3D printing has an even lesser scrap rate. Waste plastics originate from the four areas of the injection moulding process, namely the spruce, the gate locations, the runners, and any leaks from the mould. We can maintain brand consistency and reliability in every identical component produced through the process. The second component we create will be identical to the first part. Most of the designing and prototyping the parts will be done on a 3D printer and using a different material than the actual manufacturing. An injection mould tool is required to produce thousands of injection moulded prototypes. It is required to refine any kind of detailing with the injection mould tool before the mass production of the plastic article.