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Injection Molding

This document provides an overview of injection molding. It discusses that injection molding is a high-speed process that can produce complex 3D parts in high volumes. It can hold tight tolerances and produce parts with intricate details without needing much post-processing. The process works best for mass production due to high tooling costs. It also describes the basic stages of injection molding including plasticization, filling, packing, cooling, and ejection. A wide range of part sizes and applications are mentioned.

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mmanhar
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0% found this document useful (0 votes)
13 views14 pages

Injection Molding

This document provides an overview of injection molding. It discusses that injection molding is a high-speed process that can produce complex 3D parts in high volumes. It can hold tight tolerances and produce parts with intricate details without needing much post-processing. The process works best for mass production due to high tooling costs. It also describes the basic stages of injection molding including plasticization, filling, packing, cooling, and ejection. A wide range of part sizes and applications are mentioned.

Uploaded by

mmanhar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Injection Molding

 Introduction
 It is a high-speed process that can make quite large

to very small, solid parts with simple or highly


intricate 3D geometries.
 Process can hold extremely high tolerances.
 Tooling costs are high, so the process is best suited
for high-volume applications.

 Introduction
 Can produce high-gloss parts with high depth of

image and a wide variety of special effects requiring


little or no post-mold finishing.
 Insert molding allows production of parts with
integral decorative surfaces (paint films, foils,
carpet, fabric).

 Introduction
 Moldable Range of Part Sizes: As small as the

head of a pin to as large as an Automobile Bumper


or Fascia

 Current Areas of Use


 Computer Housings
 Bumper Fascias for Autos
 Electrical Connectors
 Medical Instruments
 Toys
 Appliance Housings
 Furniture

 Plastification Stage

 The first stage is the plastification stage. During this

stage, the screw rotates and pumps the polymer


material in front of the screw. This polymer cannot
flow into the mold, so it starts to collect in front of
the screw.

 Plastification Stage
 The pressure that builds up, because of the material

being forced in front of the screw, starts to push the


screw towards the back of the injection unit. When
the screw is pushed back to a pre-set distance, the
screw stops rotating. The amount of material in
front of the screw is referred as the shot size.

 Filling Stage
 When the mold closes, the screw is pushed

forward. This fills the mold to 98% full.


 This filling is done at high speed.
 If the mold was completely filled, the pressure
would be too great and would push the mold open.

 Filling Stage

 Packing Stage
 The last 2% of the part is filled during the second

stage of the injection molding cycle.


 As the molten polymer starts to cool, it shrinks.
Compensation for this shrinkage is done in this
stage. Without this compensation, the part would
shrink away from the mold walls.
 This stage is complete when the gate solidifies and
no more compensation can occur in the part.

 Packing Stage

 Cooling Stage
 When the gate is solidified, the screw builds up

another shot.
 The part is kept in the mold to solidify and retain
shape.

 Ejection Stage
 When the mold opens, the part is pushed out of the

mold.

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