Injection Molding
Injection molding is the manufacturing process where melted plastics are injected into a pre-created mold to form the shape of a specified product. This process applies to a variety of materials such as metal, glass, and rubber, but is most commonly used with thermoplastics and thermosetting polymers.
The first step in this process is to heat up the raw materials to a specific temperature (depending on the type of material) so that it becomes a liquid form and is able to flow freely. Then, the material is injected in measured batches at a high pressure into the cavity (shaped hole) of the mold.
High pressure is required in this process to ensure that all the raw material fills the cavity completely. Any miscalculations in the application of pressure can cause inconsistencies in product density and durability, as well as other potential defects. As well, the product needs to cool and cure before it is removed from the mold so that it stabilizes. If the pressure is inconsistent and the product is removed before it has cooled, it has a high chance of being deformed or defective. This entire process can take anywhere between 2 to 30 seconds, depending on the required specifications.
Since the materials require high pressure injection, the molds that the materials flow into must be crafted from high strength materials and maintain durability throughout the manufacturing process. These molds require a higher initial cost, but can be considered as an investment as each additional production run lowers its average cost.
There is also an initial time investment where all machinery needs to be calibrated and the initial run needs to be manually adjusted until all specifications are met. However, once this is complete and the results of the initial run are satisfactory, the machines are automated and can efficiently produce parts and products with minimal supervision. For medium to large size production volumes, injection molding is the best option.
At Hung Kuan, our experts can walk you through the requirements necessary to produce your products as well as the time and money involved in the process. With over 25 years of plastic manufacturing experience and 40 years of tooling experience, our expertise is your advantage. For more information about injection molding, or to inquire about any of our other services, e-mail us at info@hungkuan.com.