Mold injection molding factory processing-how to avoid common injection molding problems

2021-03-23 18:47:31 admin

Mold injection molding factory processing-how to avoid common injection molding problems




   Injection molding problems may cause as many problems as possible to customers and manufacturers




   Many important factors must be considered to ensure the consistently high quality of each component. Generally, plastic injection molding accuracy is within 0.005 inches, making it one of the most reliable processes for producing parts.




   However, the nature of the process means that defects are common for inexperienced manufacturers.




   The following are common problems encountered by plastic injection molding manufacturers and the steps they take to ensure that their components maintain high standards.




   Create accurate molds




   Creating custom molds for plastic parts is a highly skilled task. Crucially, the mold is well-suited to solve manufacturability and tooling issues, which can cause component defects such as porosity, voids, warpage, shrinkage, wrinkles and flaws, and defects within the component structure.




   Traditionally, this process relied on the skills and experience of the tool administrator. As a result, there is always trial and error before perfecting the mold. The delay of this process increases the time and cost of the injection molding process.




   Tooling and prototyping software reduces the risks associated with mold development. Tool manufacturers can now digitally simulate the mold and printing process, so they can be confident that the mold is suitable for use before it is created. In turn, this reduces the production process and enables manufacturers to deliver components to customers in a shorter time.




   avoid burn marks




   burn marks are discoloration on the surface of the component. In addition to the aesthetic issues associated with marking, burns can also cause plastic degradation. The burn marks may be caused by overheating of the air trapped in the molding machine, or it may be caused by the accumulation of resin in the mold, which may also cause overheating.




  In order to avoid burn marks, the manufacturer can reduce the speed of resin injection. This reduces the chance of air being trapped. Alternatively, the manufacturer can introduce vents or degassing systems to remove residual air. The final option is to reduce the temperature to which the plastic is heated.




   prevent flow marks




  Flow marks are wavy lines that appear on the component. It is usually because the resin cools too quickly in the molding machine, or the gate (the opening that allows the molten plastic to be injected into the mold cavity) needs to be repositioned.




   This problem can usually be solved by increasing the speed and pressure of liquid plastic injection into the mold. This will help the plastic fill the mold in a more uniform manner, which will result in a more consistent cooling of the entire mold. However, in severe cases, the mold needs to be redesigned to change the position of the gate to suddenly stop the changing direction of the molten plastic. By working with skilled manufacturers, you will be able to avoid these problems and get consistent high-quality parts.