Injection molding is becoming one of the most fast growing industries in the world which has an annual turnover ranging in billions of dollars. This process is one of the most popular and versatile methods for the mass of plastic parts, having numerous advantages over other methods of plastic molding.
What Exactly Is Injection Molding
If you look at each plastic piece or part near you, chances are it was manufactured using the injection molding process. Basically, injection molding is a manufacturing process for producing parts in big volume. It is most commonly used in mass-production processes where the same part is being created thousands or even millions of times in continuity.
During this process, polymer granules are first melted and then injected under pressure into a mold. Once injected inside, the liquid plastic cools and solidifies. The materials used during this process are typically thermoplastic polymers that can be colored or filled with other additives.
Why Injection Molding Is Effective
Injection molding is one of the more popular manufacturing processes due to the dramatically low cost per unit when manufacturing high volumes. Plus, injection molding offers high repeatability and good design flexibility. Let’s take a look at some additional reasons why injection molding is a preferred choice for mass producing parts and products.
Detailed Features and Complex Shapes
Injection molds are placed under extremely high pressure. As a result, the plastic with the molds is pressed harder against the surface of the compared to any other molding process. Because of this excessively high pressure, it is possible to add a large amount of details into the design of the piece or product. What’s more, the high pressures enables complex and intricate shapes to be easily be designed and manufactured which otherwise would have been too complex and expensive to manufacture using other manufacturing processes.
Once the injection molds have been designed to meet set specification, the actual molding process itself is incredibly fast compared to other methods of molding. The plastic injection molding process barely takes times and this allows more parts to be manufactured in succession from a single mold. The high production output rate makes plastic injection molding more cost effective and efficient over other methods of plastic molding.
The plastic injection process offers a unique option within applications where parts need to be strong or durable. During this process, it is possible to use fillers in the molds. These fillers reduce the density of the plastic while it is being molded and also is beneficial in adding greater strength to the part after it has been molded. In fields where parts need to be strong and durable, plastic injection has an option that other molding processes cannot offer.
Use of Multiple Plastics Types
One of the biggest advantages of using plastic injection molding for manufacturing parts is the ability to use multiple types of plastic at the same time. Co-injection molding is the process of introducing two compatible materials into a single injection mold where the core material is encapsulated entirely. This takes away the worry about using a specific type of plastic.
Lower Labor and Manufacturing Costs
Plastic injection molding is an automated process. A majority of the injection molding process is performed by machines and robotics which a single person can operate and control. The automatic process helps reduce manufacturing costs, as the overhead expenses are significantly reduced. Furthermore, with lower labor costs, the overall cost of the manufacturing process is reduced. Additionally, automation allows for making precise and accurate injection molds — both computer aided design (CAD) and computer aided manufacturing (CAM) allow close tolerances during the making of the molds.
Plastic injection molding creates a wide range of products for all industries in a thorough, precise and cost-effective manner. If you are interested in learning more about the plastic injection process, contact Glober Design today!