Development and Analysis of Low-Cost

Automated Injection Molding Machine

Session 2020-2024

Group Members

Muhammad Waqas 20-IE-12

Muhammad Hassaan 20-IE-14

Advisor

Dr. Wasim Ahmad

Assistant Professor

External Examiner Signature: _______________________

Project Advisor Signature:__________________________

Department of Industrial Engineering

University of Engineering and Technology

Taxila

October 2024
 Table of Contents
Chapter 1 .............................................................................................................................. 5

Introduction ......................................................................................................................... 5

1.1. Background: ............................................................................................................. 5

1.2. Project Description: ................................................................................................. 7

1.3. Working Principle: ................................................................................................... 7

1.4. Project Objectives: ................................................................................................... 8

1.5. Project Applications: ................................................................................................ 8

1.6. Sustainable Development Goals (SDG’s):.............................................................. 9

1.7. Project Planning: .................................................................................................... 10

1.8. Summary: ............................................................................................................... 11

Chapter 2 ............................................................................................................................ 13

Related Work ..................................................................................................................... 13

2.1. Development of Injection Molding Machine: .......................................................... 13

2.1.1. Hopper: ................................................................................................................ 14

2.1.2. Barrel:....................................................................................................................... 14

2.1.3. Reciprocating Screw: .......................................................................................... 15

2.1.4. Heaters: ................................................................................................................ 16

2.1.5. Nozzle: .................................................................................................................. 16

2.1.6. Ejector Pins or Extraction Pins: ........................................................................ 17

2.1.7. Split Molds: .......................................................................................................... 18

2.1.8. Clamping Unit: .................................................................................................... 19

2.1.9. Injection Unit: ...................................................................................................... 19

2.2. Classification of Injection Molding Machines: ........................................................ 20

2.2.1. Based on orientation: .......................................................................................... 20

2.2.1.1. Vertical Injection Molding machine: .......................................................... 20

2.2.1.2. Horizontal Injection Molding machine: ..................................................... 22

 2.2.2. Based on the plasticizing and injection technique of the injection machine: 23

2.2.2.1. Plunger injection machine: .......................................................................... 23

2.2.2.2 Screw Injection Machine: ............................................................................. 24

2.3. Development of Low-Cost Injection Molding Machine: ........................................ 25

2.3.1. Material Selection: .............................................................................................. 25

2.3.2. Simplified Design Principles: ............................................................................. 25

2.3.3. Energy Efficiency: ............................................................................................... 25

2.3.4. Manufacturing Techniques: ............................................................................... 25

2.3.5. Modular Design: .................................................................................................. 26

2.3.6. Localized Resourcing: ......................................................................................... 26

2.3.7. Customization: ..................................................................................................... 26

2.3.8. Innovation in Manufacturing Processes: .......................................................... 26

2.3.9. Accessibility and Democratization:.................................................................... 26

2.4. Development of Low-cost Automated Injection Molding Machine: ...................... 26

2.4.1. PLC Controllers: ................................................................................................. 27

2.4.2. Hydraulic Unit or Pneumatic Pump:................................................................. 28

2.5. Summary: .................................................................................................................... 29

Chapter 3 ............................................................................................................................ 30

Methodology ...................................................................................................................... 30

3.1. Design & Development Process: ........................................................................... 30

3.2 Automating Molding Machine .......................................................................... 33

3.2.1 Amsamotion AMX-200 ..................................................................................... 34

3.2.2 Siemens S7-200 Microwin Software ............................................................... 35

3.3. Connections: ........................................................................................................... 35

 List of Figures

Figure 1. 1 Project Phases in a Flowchart ....................................................................... 11

Figure 2. 1 Hopper............................................................................................................. 14
Figure 2. 2 Barrel............................................................................................................... 15
Figure 2. 3 Reciprocating Screw ...................................... Error! Bookmark not defined.
Figure 2. 4 Heater .............................................................................................................. 16
Figure 2. 5 Nozzle .............................................................................................................. 17
Figure 2. 6 Extraction pins or Ejector pins ..................................................................... 18
Figure 2. 7 Split Molds ...................................................................................................... 19
Figure 2. 8 Vertical Injection Molding machine ............................................................. 21
Figure 2. 9 Horizontal Injection Molding machine ........................................................ 23
Figure 2. 10 Plunger injection machine ........................... Error! Bookmark not defined.
Figure 2. 11 Screw Injection Machine ............................................................................. 25
Figure 2. 12 PLC Controllers ........................................................................................... 28
Figure 2. 13 Hydraulic Unit or Pneumatic Pump........................................................... 29

Figure 3. 1 Systematic steps to streamline the completion of the machine .................. 31

Figure 3. 2 AMX-200 PLC Schematics ............................................................................ 35
Figure 3. 3 Connections..................................................................................................... 36

. List of tables

Table 1. 1 SDG’s Mapping .................................................................................................. 9

Table 3. 1 Feasibility of Machines .................................................................................... 32

Table 3. 2 Different PLCs Model in Market ................................................................... 33
 Chapter 1

Introduction
High-tech injection molding machine imported from developed countries put extra pressure
on the import bill of countries like Pakistan. Furthermore, there is always need of qualified
manpower to operate these machines. To overcome these financial and manpower
constrains, there is a need to develop low cost and low to medium tech machines which may
tackle the local needs of community.

Therefore, this research aims to develop an economical automated injection molding

machine designed to support localized development and production of innovative products.

Leveraging low-tech mechanics and readily available manpower, the project will support to
catalyze entrepreneurship and curtail the import expenditures incurred due to conventional,
expensive injection molding equipment. The proposed injection-molding machine offers a
cost-effective solution, enabling local entrepreneurs to bring their innovative products to
market, while simultaneously reducing dependency on costly imported machinery. This
endeavor will not only stimulate economic growth but will also empower grassroots
innovation and manufacturing ecosystems.

In the contemporary section of this report, we will delve into a comprehensive examination
of the operational intricacies of the Injection Molding Machine, elucidating how it can offer
significant advantages to the manufacturing industry. Additionally, we will furnish an
exhaustive analysis of the implementation procedures, hurdles encountered during the
process, and the prospective horizons for the utilization of the Injection Molding Machine
system.

1.1. Background:
John Wesley Hyatt, an American inventor developed the first injection-molding
machine and patented it in 1972 [1]. The machine was relatively simple in comparison
with machines used today. In 1919, Arthur Eichengrün pioneered the development of
the inaugural injection molding press [1], representing a significant milestone in the
evolution of what we now recognize as the modern injection-molding machine.
Subsequently, in 1926, Eckert and Ziegler secured a patent for the first injection
molding machine possessing commercial viability. The 1930s witnessed the introduction
of the initial injection molding machines in France, signifying the commencement of
plastic consumer goods and toys entering the marketplace [1].

The machine is called injection molding machine because works on the principle of
injection molding. The principle is very easy to understand: heat the plastic until it is
viscous melt, apply pressure and force it into a die, wait for plastic to solidify, open the
die and extract the finished part [2]. Injection molding stands as a pivotal method for the
large-scale production of items crafted from thermoplastics, typically negating the need
for additional post-production refinements. In contemporary times, the majority of
injection molding machines are of the versatile variety, capable of accommodating a
wide range of molds, albeit within certain constraints. This technique boasts compelling
economic advantages, particularly for items with intricate shapes, affording it a
competitive edge over alternative approaches. Despite the substantial initial investment
required for injection molding machines, the cost per molding operation becomes
increasingly favorable as production volumes escalate.

Injection molding is a manufacturing process that involves heating a thermoplastic

polymer beyond its melting point, causing it to transform from a solid into a molten
liquid with a relatively low viscosity. This molten material is then forcibly pushed, or
"injected," into a mold designed to match the final shape of the desired product. Thanks
to the low viscosity of the molten polymer, it can completely fill the mold, taking on the
shape of the object, and then cool down until it solidifies. In the case of semi crystalline
polymers, the degree of crystallization (which affects the mechanical and visual
properties of the object) is usually regulated by cooling the object within the mold at a
specific cooling rate. In the final step of the process, the mold is opened, and the finished
part is removed and collected. The process is extremely fast and is also capable of
producing parts with complex geometries. Some researchers claim that it can produce
12 thousand to 16 thousand parts per cycle.
1.2. Project Description:
The project anchors on the development of low-cost automated injection-molding
machine, which is capable of producing innovative plastic products with excellent
surface finish and high strength. The primary focus is on the development of low cost
and low to medium tech machine to tackle the needs of the community.

The cost reduction was achieved by using locally available parts in machine
construction. To maintain high quality of the products manufactured, design of
experiments technique was used to identify the optimum machine parameters. The
developed machine was then automated using PLC controller which enabled the control
of machine parameters such as pressure and temperature to maintain the quality aspects.

Nutshell, the project will support to catalyze entrepreneurship and curtail the import
expenditures incurred due to conventional, expensive injection molding equipment. The
injection-molding machine offered a cost-effective solution, enabling local
entrepreneurs to bring their innovative products to market, while simultaneously
reducing dependency on costly imported machinery.

1.3. Working Principle:

The machine is called injection molding machine because works on the principle of
injection molding. Injection molding is a manufacturing technique that facilitates the
mass production of parts. In this process molten material is injected into a mold to
produce desired products. Materials used for injection molding encompass a range of
materials which include elastomers, glasses, metals and even edible confections.
However, it is most frequently employed with thermoplastic, nylon and thermosetting
polymers.

The method has following steps:

 The injection molding process starts by introducing resin pellets or granules into the
hopper, which serves as the material’s entrance.
 Subsequently, these pallets are then subjected to heating and melting within the
cylinder to prepare them for injection.
 The molten material is then pushed through the nozzle of the injection unit and
directed through a channel within the mold, referred to a as sprue, from where it
branches into runners, ultimately filling the mold cavity.
 Once the material cools and solidifies, the mold is opened, allowing for the ejection
of the molded part.
 Any excess material attached in the form of the sprue and runners is trimmed from the
final product.

1.4. Project Objectives:

The project is designed to achieve the following objectives.

1. Conduct a local market survey to identify existing locally developed injection

molding machines.
2. Identify design parameters for the development of an economical injection
molding machine.
3. Manufacture the automated injection molding machine using locally available
resources.
4. Analyze the impact of machine input parameters on product surface finish and
strength.
5. Develop commercial products tailored to community needs.

1.5. Project Applications:

The future scope of this project is promising and can encompass several avenues for
further development and impact. Here are some potential future scopes:

• Advanced Material Compatibility: Expand the capabilities of the injection

molding machine to work with a broader range of materials, including
biodegradable plastics, composite materials, and recycled plastics. This would
align with sustainability goals and address environmental concerns.
• Enhanced Automation: Invest in research and development to further automate
the injection molding process. This could include incorporating robotics, machine
learning, and artificial intelligence to optimize machine operation, reduce human
intervention, and improve efficiency.
• Scaling for Mass Production: Explore opportunities to scale up production of the
low-cost injection molding machines to meet increasing demand, both locally and
internationally. This might involve partnerships with manufacturing firms or the
establishment of local production facilities.
 • Market Expansion: Identify and enter new markets where affordable and
automated injection molding machines can have a significant impact on local
manufacturing and innovation.
• Product Diversification: Explore the development of a broader range of products
that can be manufactured using the injection-molding machine, opening up new
opportunities and markets.

1.6. Sustainable Development Goals (SDG’s):

This project is in harmony with the United Nations' Sustainable Development Goals (SDGs)
that pertain to Industry, Innovation, and Infrastructure, Decent Work and Economic Growth,
and Responsible Consumption and Production [2].

The following are the specific Sustainable Development Goals (SDGs) associated with the
development of automated low-cost injection molding machine.

Table 1. 1 SDG’s Mapping

Goal ID Sustainable Development Description

Goal

Goal 8 Decent Work and Economic By promoting the

Growth development of a cost-

effective injection molding

machine that can be operated
by a broader range of people,
it supports economic growth
and the creation of decent
work opportunities

Goal 9 Industry, Innovation and It aims to develop

Infrastructure innovative, low-cost, and
accessible technology in the
form of the injection
molding machine.
 Additionally, by fostering
the growth of a local
manufacturing ecosystem, it
contributes to sustainable
industrial development.

Goal 12 Responsible Consumption By enabling responsible and

and Production sustainable production
practices at the local level, it
contributes to the reduction
of waste and resource
consumption associated with
the import of conventional
machinery.

1.7. Project Planning:

The project was planned to execute in 4 phases distributed over 2 semesters which are:

I. Market Research and Design:

Conducted a local market survey and identified design parameters of the injection molding
machine.

II. Manufacturing:

Fabricated the injection molding machine using locally available resources.

III. Testing and Analysis:

Analyzed the impact of machine input parameters on product quality.

IV. Product Development:

Created and produced community-specific products using the developed machine.

V. Evaluation and Dissemination:

Evaluated the project's impact on economic growth, innovation, and manufacturing
ecosystems. Disseminated findings and knowledge.

Market Research and Design

Manufacturing

. Testing and Analysis

Product Development

Evaluation and Dissemination.

Figure 1. 1 Project Phases in a Flowchart

1.8. PLO’s Mapping:

Following PLOs have been mapped in the completion of this project,

Table 1.2 Mapped PLOs

PLOs Ch# Ch# Ch# Ch# Ch#

01 02 03 04 05

PLO1: Fundamental engineering concepts 🗸

PLO2: Research and analysis of complex engineering 🗸

problems

PLO3: Design solutions 🗸

 PLO4: Investigation of complex engineering 🗸
problems
PLO5: Use of appropriate tools and techniques 🗸

PLO6: Consideration of societal implications

PLO7: Consideration of environmental implications

PLO8: Consideration of ethical implications

PLO9: Consideration of teamwork implications

PLO10: Effective communication

PLO11: Project management
PLO12: Recognition of the need for and ability to
engage in lifelong learning

1.9. Summary
This chapter presented an overall approach to develop and analyze a low-cost automated
injection molding machine. The project objectives are integrated with project planning and
execution phases. The project’s accordance with sustainable development goals and future
developments and applications of the project are discussed in this chapter.
 Chapter 2

Related Work
In the realm of manufacturing and plastics processing, injection molding remains a
cornerstone of modern industry. Its versatility, precision, and efficiency have made it
indispensable for the mass production of a vast array of products, ranging from consumer
goods to intricate automotive components. However, the accessibility of injection molding
technology, particularly in resource-constrained environments and emerging markets, has
often been hampered by the high capital costs associated with state-of-the-art injection
molding machines.

The landscape of injection molding machine development has witnessed notable strides,
with a focus on enhancing accessibility and affordability. Researchers and engineers have
explored various avenues, ranging from the general development of injection molding
machines to more specific endeavors such as the creation of low-cost injection molding
machines. The latter, in particular, has garnered significant attention due to its potential to
democratize the utilization of injection molding technology in diverse settings, including
resource-constrained environments, small-scale manufacturing, and educational
institutions. The intersection of low-cost and automation in injection molding has also been
a prominent area of investigation, as the integration of automated features holds the promise
of streamlining the molding process while keeping costs at a minimum.

This section delves into the collective efforts aimed at advancing injection molding
technology, with a nuanced exploration of both general developments and the targeted
initiatives focused on affordability and automation. Through an examination of these works,
insights into the challenges, innovations, and future possibilities in the realm of injection
molding machine development emerge, providing a comprehensive foundation for further
exploration and progress in this vital manufacturing domain.

2.1. Development of Injection Molding Machine:

A machine which works on the principle of injection molding is called an injection molding
machine. The machine which is also known as an “injection press”, is mainly used for
manufacturing plastic products via injection molding process. The development of injection
molding machine is explained next.
Components of Injection molding machine:

The injection molding machine is comprised of the following parts.

2.1.1. Hopper:
The hopper is the part where the plastic are loaded before the initiation of the injection
molding procedure. This container generally houses a dehydrating apparatus to shield the
plastic material from moisture. It might also feature tiny magnets to deter any detrimental
metallic fragments from accessing the device. Subsequently, the plastic substance is
transferred from the container to the subsequent principal unit, termed the barrel.

Figure 2. 1 Hopper

2.1.2. Barrel:
The cylinder, also known as the material tube and barrel, elevates the temperature of the
plastic substance until it liquefies, enabling it to flow through the barrel. The internal screw
then introduces the plastic into molds or voids within the clamping unit. As a result, it's
essential to effectively control the temperature within the barrel to sustain the correct heat
levels for various plastic materials. The role of the cylinder encompasses conveying,
compressing, liquefying, stirring, and exerting pressure on the plastic prior to its arrival at
the injection mold.
 Figure 2. 2 Barrel
2.1.3. Reciprocating Screw:
Reciprocating screws, introduced in the mid-1950s, swiftly gained prominence by the
1960s, largely supplanting older systems. The key advantage of the reciprocating screw
design lies in its ability to effectively regulate the temperature of molten plastic.

This screw operates by propelling plastic material through the barrel. Initially, as pellets are
introduced from the hopper into the barrel, the screw is set in motion, propelling the material
forward while concurrently adding more pellets. Subsequently, the screw's flights initiate a
continual mixing action, ensuring uniform heat distribution throughout the mass. This
mixing action also serves to cleanse the mechanism of any residual materials and colors left
behind from prior production runs on the same injection molding machine.

The reciprocating screw plays a pivotal role in heating the thermoforming plastic. This is
achieved through a reduction in the screw's diameter as it approaches the tip. Consequently,
plastic pellets are drawn along by the flights, compressed into a more confined space, and
sectioned by the revolving flights. This process generates friction, leading to a thorough
blending of the pellets and elevating them to the desired temperature.
Figure 2. 3 Reciprocating Screw

2.1.4. Heaters:
Various types of heaters are employed in an injection molding machine to regulate
temperatures in channels, nozzles, molds, and platens. One common application is the
utilization of a heating element affixed to the barrel, facilitating the conversion of the
molding material from the hopper into a molten state. Different varieties of injection
molding heaters encompass band heaters, coil/nozzle heaters, cartridge and strip heaters, as
well as insulated cloth heating jackets.

Figure 2. 4 Heater
2.1.5. Nozzle:
The nozzle in an injection molding machine is a crucial component situated at the base of
the ejector system. Its primary role is to propel liquefied plastic from the barrel into the
mold. The nozzle makes contact with a surface on the mold known as the sprue bushing and
locating ring, which serves to center the nozzle precisely on the mold. In contemporary
applications, nozzles offer a range of functions, including filtration, mixing, and control of
melt flow.

Nozzle filters are effective at minimizing blockages in gates and hot runner tips caused by
foreign materials or contaminants present in the melt stream. Mixing nozzles contribute to
the improved dispersion and blending of additives, resulting in enhanced quality of molded
parts while simultaneously reducing the quantity and cost of additives. Shut-off nozzles
prove beneficial in reducing excess material or "drool" in injection molding processes,
particularly when the press is frequently disengaged from the mold, as is common in many
two-shot molding procedures.

Figure 2. 5 Nozzle
2.1.6. Ejector Pins or Extraction Pins:
Ejector pins play a pivotal role in the production of parts and are an integral part of the
ejection system within molds, exerting a significant influence on the outcome of products
in the injection molding process.

The metal injection mold comprises two primary halves: A and B sides. Once the molten
material within the mold has cooled and solidified, the two halves are separated to facilitate
the removal of the formed plastic component. Injection molds are strategically designed so
that upon opening, the A-side half ascends, thereby leaving the molded part within the B-
side.
Ejector pins are situated on the B-side half of the injection mold, and their purpose is to
eject or remove the formed part from the mold. This action often leaves behind a
characteristic pin mark on the finished products, appearing as a slight indentation.

A diverse range of ejector pins is available, each tailored to specific requirements. Through-
hard ejector pins are subjected to heat treatment to ensure uniform hardness across the pin's
diameter. In contrast, case-hardened ejector pins are considerably harder and are particularly
suitable for die-casting ejection systems. For applications involving high temperatures up
to 1000°C, black ejector pins are coated with a special surface treatment, providing self-
lubrication and enhanced durability.

Figure 2. 6 Extraction pins or Ejector pins

2.1.7. Split Molds:
In the realm of injection molding, a parting line is the point at which the two halves of a
mold come together upon closure, primarily in the case of split molds. The plastic product
produced through injection molding is typically divided into two distinct parts, with the line
demarcating the boundary between these two mold halves being referred to as the parting
line.

Split molds represent a specific category within injection molding, characterized by the
formation of the mold cavity by two opposing jaws. These jaws are initially injected
diagonally, typically on the nozzle side of the mold. When the mold opens, they are then
retracted diagonally to the exterior by means of a pull tab. This motion facilitates the release
of the injection-molded part from the mold.

An alternative approach involves guiding the jaws on the ejector side. In this scenario, the
jaws are manipulated, either during or after the mold's opening, often using hydraulic
cylinders or mechanical mechanisms such as springs or compressed air to achieve the
necessary motion.

Figure 2. 7 Split Molds

2.1.8. Clamping Unit:
The clamping unit plays a critical role in the injection molding process, primarily
responsible for both opening and closing the injection mold as well as ejecting the molded
products. There are two primary clamping system configurations: hydraulic and toggle.
Hydraulic clamping systems employ one or more hydraulic cylinders, while toggle
clamping systems rely on a series of interconnected linkages.

At the core of the clamping unit are two sizable clamping plates that secure the injection
mold in place. Each mold consists of two steel components attached to one of the large
plates on the clamping unit. When the machine is prepared to introduce plastic into the mold
or cavity, the clamping unit brings the two independent plates together, allowing the plastic
to flow into the cavity and take the desired form. The plastic component subsequently
undergoes cooling to solidify. Once the plastic has reached the appropriate temperature, the
clamping unit disengages the injection mold, facilitating the release of the part as it separates
from the mold halves and is collected in a designated bin.

2.1.9. Injection Unit:

The injection unit is a pivotal component within injection molding machines and comprises
several integral parts, all working in concert to achieve a specific purpose. Its primary role
is to transform raw material into a molten state and guide it into the mold. The injection unit
is typically composed of the hopper, barrel, and screw.

The process begins with polymer granules, which are first subjected to drying and then
loaded into the hopper. In the hopper, these granules are mixed with coloring pigments or
other reinforcing additives as required. Subsequently, the granules are directed into the
barrel, where they undergo a combination of actions: they are heated, mixed, and propelled
toward the mold through the motion of the screw.

Both the screw and barrel are designed with identical geometries, optimized to facilitate the
build-up of pressure to the necessary levels and to melt the material efficiently. This
coordinated operation ensures the transformation of raw material into a molten state, making
it ready for injection into the mold to create the desired products.

2.2. Classification of Injection Molding Machines:

Injection machines, often referred to as injection molding machines, serve as the primary
machinery for shaping thermoplastics or thermosets are utilized to produce a variety of
plastic products with different shapes, thanks to the use of dedicated plastic molding molds.
These machines come in numerous types and specifications, and their classification
methods are not consistently standardized. General classification methods include:

2.2.1. Based on orientation:

The above mentioned components can be arranged in two ways according to the
requirements. Based on the orientation and arrangement of the machine's key components,
injection molding machine can be classified into following two types:

 Vertical Injection Molding Machine

 Horizontal Injection Molding Machine

Both types offer several advantages and have disadvantages as well.

2.2.1.1. Vertical Injection Molding machine:

The device for clamping the mold and injection unit of a vertical injection molding
machine are aligned along the same vertical center line, and the mold opens vertically. The
two sections of the machine move up and down vertically for the purpose of opening and
closing. The injection mechanism is handled from the top because it is located at the top of
mold. For filling the mold cavities with consistency, gravity plays a vital role along injection
pressure. It has been designed with open clamps and rotary tables. The design can vary from
manufacturer to manufacturer. The modifications or specific features can be added
according to the customer’s requirements.

Figure 2. 8 Vertical Injection Molding machine

Advantages:

 Enhances flow of material and consistency of distribution of temperature.

 Offers distinct advantages for insert molding, particularly when contrasted with
earlier or simpler horizontal molding machines.
 Allows for convenient manual operation and the utilization of rotating tables to
craft inlays and combined parts.
 Occupies significantly less floor space, with a machine footprint only half the size
of traditional horizontal molding machines.
  Requires reduced pressure along with low clamping force, benefiting from the
inherent influence of gravity in the molding process.

Disadvantages:

 Removing part manually can result in a more time-consuming process.

 Parts are at risk of damage during removal, whether done by robots or human
operators.
 Achieving precise timing during manual removal can be challenging, adding
complexity to the process.
 The manual removal step can lead to varying cycle times, impacting overall
production efficiency.

2.2.1.2. Horizontal Injection Molding machine:

The device for clamping the mold and injection unit of a horizontal injection molding
machine are aligned along the same horizontal center line, and the mold opens horizontally.

As a result of this arrangement, it becomes imperative to maintain a consistent and accurate

injection pressure to effectively fill the mold cavities, ensuring the proper compaction and
cooling of the material. Horizontal molds are often equipped with a greater number of
cavities compared to their vertical correspondents resulting in an increased production of
parts per cycle. Furthermore, the horizontal orientation of the mold halves allows parts to
be automatically released from the mold cavities during the ejection phase, eliminating the
necessity for manual extraction.
 Figure 2. 9 Horizontal Injection Molding machine

Advantages:

 Enhanced efficiency in terms of the number of parts produced per cycle.

 A wider range of options is available due to its prevalence, including choices
between hydraulic or electric systems.
 Steady cycle times are attainable, enabling continuous and uninterrupted
operation.

Disadvantages:

 Insert molding is considerably more challenging and less efficient in this

configuration.
 These machines occupy a larger floor space compared to vertical molding
machines.

2.2.2. Based on the plasticizing and injection technique of the injection machine:
Based on the plasticizing and injection technique of the injection machine:
 Plunger injection machine
 Screw injection machine

The details of both along with figures are presented next

2.2.2.1. Plunger injection machine:

A plunger injection machine operates by utilizing a plunger to progressively push plastic
material, which falls into the barrel, into the plasticizing chamber situated at the front of the
barrel. Within the plasticizing chamber, the plastic is heated to a molten state by the
peripheral heater of the barrel. Subsequently, the molten material is injected into the mold
cavity through the swift forward motion of the plunger and then cooled to take its final form.
Figure provides a schematic structural representation of a plunger injection machine.

Figure 2. 10 Plunger injection machine

2.2.2.2 Screw Injection Machine:

Within a screw injection machine, plastic undergoes a process of softening and melting,
which is brought about by a combination of factors, including the generation of heat from
the external heating of the barrel and the plastic's exposure to extrusion and shearing forces
as the screw rotates. This process serves the purpose of plasticizing the material.
Subsequently, the screw reciprocates along its axis, functioning much like a plunger, to
inject the plasticized material into the mold cavity. The material is then cooled down to its
final form. A depiction of the structure of this reciprocating screw injection machine is
presented in Figure 2. Currently, this configuration is the most widely utilized among
injection machines.
 Figure 2. 11 Screw Injection Machine

2.3. Development of Low-Cost Injection Molding Machine:

The development of a low-cost injection molding machine is a transformative initiative in
the realm of manufacturing, with several key factors contributing to its affordability.

2.3.1. Material Selection:

We prioritize cost-effective yet durable materials, optimizing choices for a balance between
affordability and performance.

2.3.2. Simplified Design Principles:

Adopting streamlined and simplified design approaches reduces complexity, and our
commitment to innovative engineering ensures efficient yet economical designs.

2.3.3. Energy Efficiency:

Optimizing the machine's power consumption is a key focus, incorporating energy-efficient
components and systems for overall cost savings.

2.3.4. Manufacturing Techniques:

Utilizing advanced manufacturing techniques, such as precision machining and 3D printing,
enables the creation of intricate parts at a lower production cost.
2.3.5. Modular Design:
Our design philosophy embraces modular principles, enhancing customization capabilities
and prioritizing easy assembly and maintenance to reduce development expenses.

2.3.6. Localized Resourcing:

We source materials and components locally, minimizing transportation costs and
promoting availability in regions with limited resources.

2.3.7. Customization:
Our design philosophy prioritizes flexibility, ensuring easy adaptation to different
production requirements and meeting diverse manufacturing needs.

2.3.8. Innovation in Manufacturing Processes:

Exploration of innovative approaches in manufacturing processes seeks cost-effective
solutions, and our commitment to technological advancements contributes to overall cost
reduction.

2.3.9. Accessibility and Democratization:

We aim to make injection molding technology accessible to a broader audience, promoting
innovation and sustainability by democratizing access to economically viable
manufacturing capabilities.

2.4. Development of Low-cost Automated Injection Molding Machine:

The developed machine is then Automated Injection Molding Machine utilizing
Programmable Logic Controller (PLC) technology and Pneumatic Cylinders representing a
significant advancement in manufacturing automation. This innovative system integrates
PLC, a digital computing platform, to control and monitor the injection molding process
with precision. The PLC orchestrates the entire sequence of operations, from material
feeding to mold closing and ejection, ensuring accuracy and repeatability in the production
cycle.

Pneumatic cylinders play a pivotal role in this automated setup, providing the necessary
force to drive key actions in the molding process. The PLC, through programmed logic,
commands the pneumatic cylinders to actuate specific movements, such as clamping the
mold, injecting the material, and ejecting the finished product. This seamless coordination
enhances operational efficiency, reduces cycle times, and minimizes the risk of errors.

The synergy between PLC and pneumatic technology not only streamlines the injection
molding process but also offers adaptability and ease of control. Operators can fine-tune
parameters through the PLC interface, allowing for quick adjustments to accommodate
different molds or material specifications. Additionally, the integration of pneumatic
cylinders contributes to energy efficiency and faster response times, enhancing the overall
performance of the automated injection molding machine.

2.4.1. PLC Controllers:

A programmable logic controller (PLC) functions as a miniature computer capable of
receiving data through inputs and issuing operating instructions through its outputs.
Essentially, the PLC's primary role is to govern a system's functions using the internally
programmed logic. Businesses globally employ PLCs to automate critical processes,
streamlining operations and improving efficiency.

PLC maintenance involves handling inputs, sourced from automated data capture points or
human inputs like switches and buttons. Based on its programmed logic, the PLC determines
whether to alter the output. The outputs of a PLC have the capacity to control a diverse
range of equipment, including motors, solenoid valves, lights, switchgear, safety shut-offs,
and more.

The physical placement of PLCs varies across systems, but they are typically situated in
proximity to the systems they operate. Additionally, they are commonly housed within
surface mount electrical boxes for protection. PLCs emerged as a replacement for manual
relay-based control systems prevalent in older industrial facilities. Richard Morley
introduced the first PLCs in the 1960s as a more reliable alternative to complex and failure-
prone relay systems. Recognizing their potential, manufacturers swiftly integrated PLCs
into their work processes.
Even today, PLCs remain a foundational component of numerous industrial control systems,
standing as the most widely used industrial control technology globally. Proficiency in
working with PLCs is a prerequisite skill for various professions, spanning from system
design engineers to electrical technicians tasked with maintenance.

Figure 2. 12 PLC Controllers

2.4.2. Hydraulic Unit or Pneumatic Pump:
In plastic injection molding machines, the hydraulic system or unit is a fundamental
component, often operating continuously throughout production cycles. Several key sub-
circuits are initiated by motion, including the approach of the nozzle, the injection of the
plunge screw, the rotation of the extruder screw, and the closure of the mold. These motions
are critical for ensuring the smooth flow of granular plastic material through the heated
plasticized state and into the mold during the screw rotation and plunge phase. Any
irregularities in these hydraulic motions can potentially compromise the quality of the
injection-molded product.

Force control sub-circuits are also essential to maintain the mold's closed position and
secure the nozzles along the sprue of the injection mold. These functions are particularly
crucial during the injection molding process, where the adjustment and monitoring of
hydraulic pressure play a pivotal role in controlling mechanical pressure.

The system responsible for moving the screw, which is powered by a hydraulic motor, in
conjunction with the cylinder that propels the screw forward, forms a complex mechanism.
This mechanism necessitates precise hydraulic seals, particularly during the injection and
packing phases of the mold. Modern advancements in seal technology have led to the
development of leak-free hydraulic machines that are not only suitable for molding plastic
products but can also meet the stringent requirements of industries such as medical and food
production.

Additional integral components of the clamping unit encompass machine ejectors, a

movable platen, a stationary platen, and tie bars. These elements collectively contribute to
the efficient operation of the clamping unit during the injection molding process.

Figure 2. 13 Hydraulic Unit or Pneumatic Pump

2.5. Summary:
This comprehensive exploration, as detailed in this section, sheds light on the collective
efforts driving innovation in injection molding technology. Insights gained from both
general developments and targeted affordability and automation initiatives provide a robust
foundation for ongoing exploration and advancement in this crucial realm of manufacturing.
 Chapter 3

Methodology
In this chapter, we have discussed the methodology we adopted during the development of
the machine. The methodology intricately aligns with the project's overarching objectives.
The initial objective, involving a local market survey to identify existing injection
molding machines, resonates with the project's aim to understand the landscape and user
needs. Subsequently, the identification of design parameters mirrors the objective of
developing a low-cost automated machine. The manufacturing phase corresponds to the
practical realization of the project's goal, emphasizing the utilization of locally available
resources. Analyzing the impact of machine input parameters on product quality directly
addresses the objective of ensuring the efficiency and effectiveness of the developed
solution. Finally, the development of commercial products for the community is the
ultimate objective, signifying the project's aspiration to provide a viable and accessible
injection molding solution. In essence, each step in the methodology seamlessly maps
onto the specific objectives, collectively contributing to the overall success of the project.

3.1. Design & Development Process:

This section presented the detailed steps to complete the development injection molding
machine. It involved the systematic steps to streamline the completion of the machine.
 SOLIDWORKS design

Sourcing and Processing of parts

. Assembly

Connections and Automation

Testing and Analysis

Figure 3. 1 Systematic steps to streamline the completion of the machine

3.2. Developing Injection Molding Machine:

An injection molding machine is a crucial manufacturing apparatus used in the production
of plastic parts and components. This versatile machine enables the efficient and precise
shaping of plastic materials by injecting molten plastic into a mold cavity, where it solidifies
to take on the desired form. They play a pivotal role in the manufacturing industry,
especially in sectors like automotive, consumer goods, electronics, and medical devices.
The machines' efficiency, accuracy, and ability to produce complex shapes make them
indispensable for mass production of plastic components. Advances in automation and
technology continue to enhance the precision and speed of injection molding processes,
contributing to the overall evolution of this key manufacturing technique. For our design,
we considered different types of parameters and studied their feasibility and then selected
vertical injection molding machine for the design. Both types of machines are present in
table
 Table 3. 1 Feasibility of Machines

Machine Feasibility Image Description

Type
Horizontal Enhanced efficiency in terms of the
number of parts produced per cycle.

A wider range of options is available

due to its prevalence, including
choices between hydraulic or
electric systems.

Steady cycle times are attainable,

enabling continuous and
uninterrupted operation.

Vertical Occupies significantly less floor

space, with a machine footprint only
half the size of traditional horizontal
molding machines.

Requires reduced pressure along

with low clamping force, benefiting
from the inherent influence of
gravity in the molding process.

Thus, we selected vertical injection molding machine to develop.

3.2 Automating Molding Machine
PLC or Programmable Logic Controller is an industrial computer that is used to control and
automate manufacturing processes. In this project, we used PLC with Step 7 MicroWin
software to automate the conveyor system. Ladder logic, a programming language used in
PLCs, was created on Step 7 MicroWin software to control the conveyor's speed, start and
stop at each workstation.
In the market, there are several types of programmable logic controller (PLC) models
available, each with its own unique features and capabilities. These PLC models come in
different forms, including compact PLCs for applications with limited space, modular
PLCs that offer flexibility and scalability, rack-mounted PLCs for larger-scale applications,
and integrated PLCs that combine PLC functionality with other components like HMI
panels or touchscreen displays.
Furthermore, PLC models are designed to meet specific requirements and challenges of
industrial automation. Some models focus on high performance, advanced communication
capabilities, and extensive I/O options. After thoroughly exploring the available factors
associated with different available models of PLCs, AMX-200 is selected for the
automation of conveyor system.

Table 3. 2 Different PLCs Model in Market

Company PLC Model Features and Image Description

Capabilities
Siemens SIMATIC High performance,
S7-1500 modular design,
advanced
communication
capabilities, extensive
I/O options

Amsamotion AMX-200 Cost-effective, compact

size, multiple
communication
protocols, wide range of
I/O options
 Rockwell AllenBradley Compact and modular
PLCs designs, scalable, wide
range of I/O modules,
advanced programming
options

Schneider Modicon Versatile, modular

Electric M340 architecture, extensive
communication options,
user-friendly
programming

Mitsubishi MELSEC- Fast processing,

Electric Q Series highspeed I/O, large
memory capacity,
advanced motion
control
capabilities

3.2.1 Amsamotion AMX-200

The AMSAMOTION AMX-200 PLC (CPU 224XP) is a compact and versatile
programmable logic controller designed for industrial automation. It offers 14 digital inputs
and 10 digital outputs, along with analog input and output capabilities. The PLC supports
various communication protocols, including Modbus and USS. With a high-speed counter
for up to 6 axes and a capacity of 20K, it provides efficient and reliable control in
automation systems.
 In/P Terminals

Power Supply 220 V-AC

PLC Start/Stop
Run
Error Message

Output Terminal 24V-DC O/P

Figure 3. 2 AMX-200 PLC Schematics

3.2.2 Siemens S7-200 Microwin Software
Siemens S7-200 Microwin Software is a programming environment specifically designed
for the Siemens S7-200 series of programmable logic controllers (PLCs). It provides a user-
friendly interface that allows engineers and programmers to create ladder logic programs
for industrial automation applications.
The Microwin Software offers a comprehensive set of tools and features for ladder logic
programming, including graphical editing, debugging, and online programming
capabilities. It is compatible with various industries and is widely used in manufacturing,
process control, and machine automation. The software simplifies the development and
maintenance of ladder logic programs, enabling efficient control and automation of
industrial processes.

3.3. Connections:
The hydraulic connections of the machine are as follows. Air from compressor geos to the
pressure regulator which then directs air according to the set pressure to the input of
solenoid valve. The valve then controls the pneumatic cylinder attcahed aaccording to the
time set.

Figure 3. 3 Connections