Integral Manufacturing https://integralmfg.com Integral to Your Success Tue, 16 May 2023 05:29:20 +0000 en-US hourly 1 https://wordpress.org/?v=6.4.3 https://integralmfg.com/wp-content/uploads/2016/02/cropped-512x512-1-3-32x32.png Integral Manufacturing https://integralmfg.com 32 32 Everything You Need To Know About Progressive Metal Stamping https://integralmfg.com/blog/everything-about-progressive-metal-stamping/ Thu, 20 Apr 2023 10:08:51 +0000 https://integralmfg.com/?p=2238 What Is Progressive Stamping? Progressive stamping is a forming process that uses dies and presses to shape a metal sheet or strip into the required form. The metal sheet is fed through the press, and each press has a different die that transforms the metal into a more complex structure. Then, the sheet moves from one press to the next until it reaches its final shape. The process is highly automated and can produce a large number of parts in a short amount of time. Each die in the press performs a specific operation — such as cutting, bending, or drawing — to transform the metal sheet into the required configuration.

Benefits of Progressive Stamping

The advantages of this type of metal stamping make it a cost-effective and efficient forming process suitable for high-volume production runs of complex parts. Here are some of the most significant advantages of utilizing the technique:

Complex Shapes

Progressive stamping is highly effective in producing complex shapes and designs, which would be challenging or unfeasible to achieve through other forming methods.

Consistency and Repeatability

Using automated equipment and standardized processes in the stamping process significantly reduces the risk of defects and variations in part dimensions. Since each die in the press performs specific functions, it results in precise and consistent parts that meet the required quality standards. Furthermore, it allows using quality control measures like statistical process control and dimensional analysis.

Cost-Effectiveness

A single metal sheet to produce multiple parts reduces material waste and production costs. It also eliminates the need for secondary operations — such as trimming and piercing — which can lead to further savings.

High-Speed Production

Progressive stamping is preferred for producing large parts due to its high-speed production. This process uses dies and presses that are operated continuously and automatically, resulting in fast and efficient production with minimal downtime.

Industrial Applications of Progressive Stamping

Progressive stamping is a versatile process used in various industries. Below are some examples of the industries that commonly use this process and the types of parts produced:

Aerospace

The aerospace industry requires precision and reliability in producing its components, making stamping a popular choice. It produces aircraft components such as wings, fuselages, and landing gear. Progressive stamping also allows for complex shapes and designs, which is ideal for aerospace applications requiring the highest level of precision and quality.

Automotive

The automotive industry uses stamping to produce vehicle parts, such as body panels, brackets, and other structural components. Progressive stamped parts are often made with high precision and accuracy to meet the safety and performance requirements of the industry.

Electronics

The electronics industry is known for its demand for high-quality components that meet requirements such as size, shape, and material properties. The technique offers an effective solution for producing parts that fulfill these requirements with precision and accuracy. Examples of common progressive stamped products include brackets, enclosures, and heat sinks.

Integral Manufacturing: Your One-Stop Shop for Stamping Services

Integral Manufacturing is committed to delivering high-quality work, particularly regarding safety-related products! Our services include progressive stamping, plastic injection molding, assembly welding, and custom automation solutions. Choosing us means outsourcing confidently, knowing you are partnering with a team dedicated to meeting your needs with excellence! Contact us today to learn how we can help you with your stamping needs and more. ]]>
Key Considerations in Design for Plastic Injection Molding https://integralmfg.com/blog/considerations-design-plastic-injection-molding/ Tue, 28 Mar 2023 07:25:05 +0000 https://integralmfg.com/?p=2221

Click to ExpandKey-Considerations-in-Design-for-Plastic-Injection-Molding
Designing for plastic injection molding is a complex process that requires careful consideration of several factors. This helps ensure the finished product is high quality, cost-effective, and manufacturable. The following are the top 10 most important things to keep in mind:

1. Material Options and Consequences

The specifications of the component and injection molding procedure should guide the selection of the material. Many material attributes — strength, flexibility, durability, and cost — affect the end product and the production process.

2. Critical Tolerances

Tolerances are the permissible deviation from the nominal dimension of a component. Critical tolerances must be met to guarantee that a component operates as intended. Therefore, critical tolerances should be carefully evaluated in a design for plastic injection molding to ensure they can be held throughout manufacture.

3. Sink Marks

Sink marks are surface depressions that can form on a component if the material cools and shrinks unevenly. Changes in wall thickness or the presence of thick and thin parts can also produce them. To eliminate these, the design should work well with injection molding, and the wall thickness should be consistent.

4. Steel Safe Areas

Steel safe areas are mold sections where the plastic cannot flow. They are required to avoid mold or component damage during the injection molding process. While designing for plastic injection molding, steel safe regions should be considered to ensure the design suits the mold and manufacturing process.

5. Gate Location

The gate is the entry point for plastic into the mold. The position of the entrance is a crucial factor in a design for plastic injection molding since it can affect mold fill and the end product. Therefore, the gate should be prepared, so the plastic flows uniformly into the mold, avoiding flaws and assuring constant filling.

6. Shut-Off Angles

Shut-off angles are the angles at which two mold surfaces meet. They are important to prevent flash or excess material from spilling out of the mold. When designing for plastic injection molding, shut-off angles should be considered to ensure that the part can be easily removed from the mold without damage.

7. Draft Angle Orientation

Draft angles are necessary for mold removal. They should be included in the component so that it may be withdrawn from the mold without causing harm to the part of the mold.

8. Texturing and Draft

Texturing is the addition of a pattern or texture to the surface of a component. It can be utilized to improve the aesthetics or grip of the element.

9. Scheduling of Critical Start-Up Phases

The start-up phases of the injection molding process are critical to ensuring that the final product is of high quality. Hence, scheduling critical start-up stages like material handling and mold temperature control optimizes manufacturing and ensures product uniformity.

10. Secondary Operations and Fixtures

Secondary procedures, such as machining or assembly, may be required to finish the final product. Fixtures may also be required to keep the item in place during the injection molding. Thus, these should be addressed in a design for plastic injection molding to ensure they don’t affect the process or component.

Integral Manufacturing: Your Reliable Partner for Plastic Injection Molding

Since 1987, Integral Manufacturing has provided high-quality, customer-specific contract manufacturing. In addition, WTTM, West Troy, and RK Metals offer additional production capabilities to meet various customer needs, including plastic injection molding. Contact us today, and we will gladly help you with your custom plastic injection molding needs! ]]>
Minimizing the Cost of Plastic Injection Molding https://integralmfg.com/blog/minimizing-cost-plastic-injection-molding/ Tue, 21 Feb 2023 05:28:45 +0000 https://integralmfg.com/?p=2039

Click to ExpandMINIMIZING-THE-COST-OF-PLASTIC-INJECTION-MOLDING

Saving money while investing in advanced manufacturing processes can be challenging, especially when dealing with intricate pieces with numerous materials and colors. However, there is always a way to improve how you manage your expenses.

Plastic injection molding can help your company improve operations and save on extraneous expenses. The cost of plastic injection molding may seem steep upfront, but its long-term benefits ensure an excellent ROI.

This article will dive into cost-cutting tips you can apply to your next project.

5 Ways To Reduce the Cost of Plastic Injection Molding for Your Applications

Here are five steps to reduce the cost of your injection molding process.

1. Enhance Operational Efficiency

It’s beneficial to always find ways to streamline every step of your manufacturing process to find areas for improvement. Finding and using the best practices in design can help you save money on any project. One way to do this is by choosing local manufacturers to decrease lead times while eliminating shipping costs.

2. Modify Designs

If you want to adjust the project’s overall cost, consider making design tweaks and lessening complex patterns. The less material utilized, the lower the overall cost of the produced plastic part. 

However, design modification should always be performed without jeopardizing the product’s overall structural integrity. To ensure the best possible outcome, discuss your design options and your budget with your plastic injection molding service provider.

3. Select Appropriate Materials

It’s crucial to remember that the most expensive, highest-rated, and state-of-the-art raw materials are not always ideal for your project. It may be classified as the “best,” but if its qualities aren’t appropriate for your items, it may cost you more with no added value. As a result, always use the most suitable materials for the product being created.

4. Reduce Customizations

You may cut expenses more by reducing the customization needed for the molded product. Unnecessary customizations and specifications often only add overhead costs without altering the quality of your product. Hence, it is critical to thoroughly analyze the requirements of each component before starting the project. 

5. Utilize Family Molds

Using a family or multi-cavity mold is a great way to reduce the cost of plastic injection molding services. Because each cavity can make a plastic design in a single run, the family mold can produce plastic patterns quickly. This technique may be more expensive in tooling, but it will have reasonable injection molding costs per part. 

Cost-Effective Plastic Injection Molding at Integral Manufacturing

Whatever upcoming projects you have, there’s a high chance you’re searching for solutions to save money. In that case, you may implement these five tips and work with a reliable manufacturing partner to accomplish your project within your budget.

Since 1987, Integral Manufacturing has been a reputable contract manufacturer offering high-quality, customized services to customers. The additional manufacturing capabilities that our companies — WTTM, West Troy, and RK Metals — possess allow us to meet various customer demands, notably those involving plastic injection molding.

Contact us today to learn more about our solutions!

]]>
How To Choose Your Custom Plastic Injection Molding Manufacturer https://integralmfg.com/blog/choose-custom-plastic-injection-molding-manufacturer/ Wed, 08 Feb 2023 08:21:16 +0000 https://integralmfg.com/?p=2024 Click to ExpandHOW-TO-CHOOSE-YOUR-CUSTOM-PLASTIC-INJECTION-MOLDING-MANUFACTURER

The plastic injection molding method is not a one-size-fits-all procedure, as it can differ from one customer to another. Your project requirements may also vary depending on your industry, product design, production timeline, and budget. Thus, successful custom plastic injection molding always begins with selecting a manufacturer whose capabilities match your project’s specifications.

Even with so many companies and manufacturers readily available, choosing the ideal partner doesn’t have to be painstaking. Instead, you may consider a few essential things to streamline the process and ensure that you select the most suitable manufacturing company.

Key Considerations When Selecting the Right Custom Plastic Injection Molding Manufacturer

Finding a manufacturing partner who can or is willing to meet your specifications is necessary to ensure your project’s success. These criteria include the capability to produce complex parts while adhering to your unique industry needs, standards, and budgetary limitations. 

The following are the key considerations when selecting a plastic injection molder:

Expertise and Quantity Specialization

Before forming a partnership, you must have a thorough understanding of the objective of your project, the operating conditions of the parts and components, and the number of custom parts required. Then, your manufacturing partner should have the knowledge and experience necessary to achieve the objectives of your project. 

Determine whether a manufacturer is a low-, moderate-, or high-volume molder. Typically, high-volume molding companies accept orders requiring over 750,000 components and manufacture them using small-sized molds. On the other hand, low- to moderate-volume molders produce fewer than 10,000 parts. 

Efficiency and Quality

Your manufacturing partner should be reputable and committed to providing the best quality service. Consider the following questions while assessing prospective partners:

  • Are they equipped with high-quality and efficient machines necessary to meet all project specifications? 
  • Do they have competent staff members with relevant project management experience?
  • Have they previously worked with the selected resin and materials?
  • Do they have procedures and systems to effectively control the material flow for large-scale production?
  • Are they known as a premium manufacturer in the industry?

Product Application

The desired product application is crucial and must be identified and finalized before designing. Consequently, ensure that the injection molders are skilled to give appropriate recommendations regarding product designs, materials, and production processes.

Compliance With Specifications and Regulations

Choose a manufacturer who can produce your components without compromising specs and standards. Feel free to ask them for recommendations or project solutions based on your needs and requirements. These solutions may include small design modifications, material selection, and other approaches that can help you save money and time.

You should also consider partnering with an ISO-certified manufacturer to verify their commitment to product quality. 

Time and Budget

Custom mold construction can take weeks and even months, depending on the complexity of the process. Hence, it is recommended to communicate your timeframe to a potential partner and verify whether they can meet it.

After narrowing down the list of manufacturers that fit your requirements, start requesting quotes from them. Make sure you have a comprehensive summary of your project ready to present, as this will aid them in providing an accurate estimate.

Integral Manufacturing for Quality-Assured Contract Services

Since 1987, Integral Manufacturing has been a reputable contract manufacturer offering high-quality, customer-specific services. In addition, our companies — WTTM, West Troy, and RK Metals — offer complementary manufacturing capabilities that allow us to meet various customer requirements, including plastic injection molding.

Contact us today, and we will be happy to assist you with your custom plastic injection molding needs!

]]>
Understanding the Different Types of Plastic Injection Molding https://integralmfg.com/blog/understanding-types-plastic-injection-molding/ Fri, 03 Feb 2023 09:40:57 +0000 https://integralmfg.com/?p=2015 Click to ExpandUNDERSTANDING-THE-DIFFERENT-TYPES-OF-PLASTIC-INJECTION-MOLDING

Injection molding is a cost-effective technique to manufacture a high volume of similar goods by injecting molten materials into a mold. Although the method is most frequently used with thermoplastic and thermosetting polymers, it may also be applied with metals, glassware, elastomers, and confections.

This article will dive into the types of plastic injection molding, their definitions, and their specific applications.

Metal Injection Molding

Niche industries may use metal over plastic in injection molding to achieve certain product specifications. This process is especially vital for electronics and digital goods production processes. Since many markets demand components with complex shapes, metal injection molding is quickly becoming one of the more prevalent manufacturing techniques.

Overmolding

Overmolding makes it feasible to make a component out of two or more polymers. A substrate (typically the initial material) is covered with secondary materials — such as overmold materials — to achieve unique product requirements for each item.

Overmolded goods are commonly used to make everyday items, such as attachments for tools or personal care products.

Insert Molding

Although this procedure is comparable to overmolding, insert molding has more material restrictions since it uses sub-materials to fill in the spaces between the pieces, increasing its strength. You may combine two or more components to make a single product by adding your selected polymer to the insert.

Insert molding parts are generally durable because they reduce the need for extra pieces, which might make the product bulkier yet less useful.

Gas-Assisted Injection Molding

This injection molding technique shields the formed components against damage or distortion after the cooling process. To retain its flawless finish, it processes pieces by injecting gas into an injection mold filled with plastic.

Gas-assisted injection molding is ideal for components requiring hollow sections, as this process can achieve said sections without adding to the cost.

Thin Wall Molding

Thin wall molding is the best method for producing components with incredibly thin walls and reducing fractures on the molded product. Since it may be utilized for tiny pieces, this process is highly accurate. Electronics, medical equipment, tubes, and other items frequently use this technique.

Thermoplastic Injection Molding

The electronics and automotive industries rely heavily on thermoplastic polymers for various purposes because they have the benefit of being conductive and strong. Thermoplastic injection molding features a reduced risk of component damage and shrinks resistance. Moreover, its high adaptability and sustainability make it a good method for companies with rigorous standards for design and functionality.

Liquid Silicone Injection Molding

High-end medical equipment and auto parts can benefit greatly from this technique since silicone is highly resistant to extreme temperatures. When creating a component, the material is injected using a heated mold. Then, a cold material is injected to chill the material and form the part.

Hot Runner Molding

Hot runner molds use heat as their primary agent. This technique is used for plastic resins that need to be heated inside or outside to materialize. It uses two heat-resistant plates that can handle small to big pieces.

Cold Runner Molding

Cold runner molding often requires three plates, unlike hot running molding. This process is preferred among manufacturers, and numerous businesses have recognized the benefits this approach offers for production. With robotic runners removal aid, cycle times for this system are significantly faster.

Need Assistance in Your Manufacturing Needs?

Molding industry experts can provide you with resources to make the most of the types of plastic injection molding to satisfy your design requirements. With Integral Manufacturing, we offer solutions that meet your demands and exceed your expectations!

To provide our clients with the best overall injection molding services, we have a wide variety of design, engineering, modeling, prototyping, testing, and production capabilities.

Find out more about Integral Manufacturing’s services here. Ready to get started? Send us an email, and we will be delighted to assist you!

]]>