From toy blocks to space shuttle turbine blades, plastic injection molding is a part of our daily life. But what is plastic injection molding? Why is it famous? And is it the right choice for your manufacturing needs? Today, we will answer all your questions about plastic injection molding and ensure you make the right choice for your business. Let’s get started!
What is Plastic Injection Molding?
Plastic Injection Molding was first introduced by an American Inventor in 1872. He attempted to replace ivory billiard balls with plastic balls, which gave him a new product quality. Since the machine’s inception, injection molding has evolved from producing small plastic components like buttons to manufacturing complex medical equipment.
The plastic injection molding process includes injecting molten plastic into a precisely engineered mold or cavity. After the plastic cools & solidifies, it takes the shape of the final product. Due to its capability to produce parts in large volumes with high dimensional accuracy, plastic injection molding is widely used across various industries, such as automotive, consumer goods, electronics, and medical devices.
How does Plastic Injection Molding work?
Plastic injection molding, introduced by an American inventor in 1872, began with the creation of plastic billiard balls. Since then, it has advanced to produce complex medical equipment and various components. The process involves injecting molten plastic into precise molds, which then cool and solidify into high-accuracy parts. It is extensively used in automotive, consumer goods, electronics, and medical industries for its efficiency and accuracy.
The plastic hardens into the mold’s shape in less than a minute. The mold then opens, and the new plastic part pops out. Once the part is out, the process can start all over again.
Why should you choose Plastic Injection Molding for your manufacturing needs?
Plastic manufacturing, including plastic injection molding, is rapidly expanding in the U.S. Since 1980, jobs in this sector have grown 1.5% annually, outpacing other manufacturing fields. Discover why U.S. manufacturers favor plastic injection molding and explore its key benefits.
Mass Production
Injection molding is one of the speedy manufacturing methods worldwide, eventually making this process suitable for mass production in less time. One injection molding cycle usually takes less than a minute—sometimes, it only takes a few seconds! Each cycle can make many parts at once, meaning many parts can be made quickly.
Low Wastage
Plastic injection molding offers a more efficient and eco-friendly alternative to CNC machining. Unlike CNC, which wastes material by cutting from larger blocks, injection molding minimizes waste, using only about 20g of raw material to produce a component from an initial 100g. This process is both cost-effective and environmentally friendly.
Complex Parts
Plastic injection molding can make very detailed parts. This means you need fewer parts to make something, saving time. You can make parts with threads or side holes by adding things like unscrewing fixtures and core pulls. This removes the need for extra steps in other processes. You can even mold your design or brand onto the part during manufacturing.
Low cost (in the long run)
Plastic injection molding wastes less material than other methods, like CNC machining, which makes it cheaper. Plus, plastic costs less than metals and rubber.
Recycling saves money, too. Leftover plastic can be ground up and reused. This leftover plastic is called “regrind.” If you have enough regrind, mix it with new plastic and use it again. You can also sell it to factories that make plastic parts that don’t need to look perfect, making the process even cheaper.
After you pay for the mold, it doesn’t cost much to run it. Over time, the mold can produce many parts, saving you money.
Consistent Quality
Plastic injection molding is a process you can repeat many times. You can make thousands of plastic parts in one day with a machine. All the parts will be almost the same.
If you design the mold well, pick the right materials, and plan the product correctly, the number of bad parts will be very low, less than one percent. Plastic injection molding is a great choice if you need your parts to be consistent.
What plastic can be used for injection molding?
Plastic part makers use thermoplastics for injection molding. Thermoplastics are special polymers that melt when heated and harden when cooled. You can heat and cool them many times before they become unusable.
Thermoplastics come as small pellets for molding. These pellets can be mixed with colors, recycled materials, glitter, and other additives. Unlike thermoset plastics, thermoplastics won’t burn if reheated. Here are the most common types of plastic used in Plastic Injection Molding:
Acrylonitrile Butadiene Styrene (ABS)
ABS is a tough and light material. It’s commonly used for making plastic parts through injection molding. For example, LEGO bricks are made from ABS.
Polycarbonates
Polycarbonates are clear, tough plastics that resist impacts and can bend very much without cracking. People use them for everything from eyewear lenses to medical devices and mobile phone screens. They’re even strong enough to be used in bullet-proof glass.
Nylon
Nylon is known for its unique electrical properties and durability. It’s a versatile thermoplastic used in everything from sports gear to industrial parts. Its strength and electrical qualities make it a go-to material in many fields.
Polypropylene
Polypropylene is a versatile material known for its flexibility. It offers excellent chemical resistance and won’t leach into food, making it a great choice for making food containers and utensils.
Polyethylene
Polyethylene is a great plastic for making things with injection molding. It’s very flexible, strong, and can handle hits without breaking. It doesn’t soak up much water and can be recycled, so it’s perfect for making plastic containers and bags.
Conclusion
Plastic injection molding is essential in modern manufacturing. Mastering this technique is crucial for launching new products or optimizing processes. Selecting reputable mold makers and molding partners ensures quality production, helps achieve goals, and maintains a competitive edge.
Frigate provides various injection molding services to meet your production needs. Check our website for everything we can do, or get a quote today!
