Plastic Injection Molding
Injection molding is one of the most widely employed manufacturing techniques for fabricating plastic parts. This process can create a vast range of goods that vary widely in size, complexity, and application.
Integral Manufacturing specializes in innovative plastic injection molding. We provide a comprehensive manufacturing solution that includes raw material verification, tool creation, component fabrication, finishing, and final inspection. In addition, our professionals are dedicated to providing you with the best professional assistance for any size or complexity of requirements.
The Plastic Injection Molding Process
Plastic injection molding is done by filling a mold tool with liquid plastic resin under high pressure. The tool may have a single cavity or hundreds of cavities to produce infinite parts. After the mold tools have been properly developed and constructed, the process consists of the following fundamental steps:
Step 1: Clamping
The clamping unit holds the mold together before injection. Here, the machine presses the two halves of the mold together to prepare for the next step.
Step 2: Injection
In this step, plastic granules or pellets are completely melted. The liquid is then pumped into the mold. Manufacturers must keep hold to maintain a constant temperature steady throughout this stage of the process.
Step 3: Dwelling
During the dwelling phase, the melted plastic fills the mold. Then, direct pressure is applied to the mold to guarantee that the liquid fills every cavity.
Step 4: Cooling
In cooling, manufacturers leave the mold to settle so that the heated plastic may cool and solidify into a usable product.
Step 5: Mold Opening
Once the part has cooled, a clamping motor will progressively release the two parts of the mold, allowing the finished product to be removed safely and easily.
Step 6: Ejection
An ejector bar progressively pushes the solidified product out of the open mold cavity while the mold is open. Next, the fabricator may utilize cutters to remove any excess material and perfect the final product for utilization by the customer.
Benefits of Plastic Injection Molding
Plastic injection molding is an extremely versatile method of fabricating plastic components that offers numerous benefits over other plastic molding methods. The process is not only easier and more reliable in different ways, but it is also incredibly efficient.
The following are the advantages of employing this method:
Injection molding can produce intricate parts in huge quantities with high consistency, minimal waste, and a low percentage of faulty parts.
This technique has the lowest labor costs compared to all other methods of producing plastic products. The molding machinery automates a significant amount of the cycle, expediting the procedure and reducing labor-associated expenses.
Custom plastic injection molding produces a wide range of products with high precision. Even the most intricate designs are accurate to within +/- .001 of an inch of tolerance. Moreover, such tolerances can be replicated over thousands of produced components.
Though injection molding produces less post-production material waste than many other manufacturing processes, it still produces excess scraps. However, you may easily regrind, melt, and reuse sprues, runners, or other leftover plastic pieces to save money and reduce waste.
Plastic injection molding is an incredibly flexible method that allows for many combinations of materials, colors, and qualities based on the exact application requirements. This enables meticulous fine-tuning of end-product features and characteristics.
Industries Utilizing Plastic Injection Molding
The injection molding method has various advantages: complexity, cost-effectiveness, preciseness, reusability, and flexibility. Here’s a list of industries that commonly rely on injection molding:
- Food and beverages
- Medical and pharmaceutical
- Building and construction
- Other consumer products
Choose Integral Manufacturing for Top-Quality Plastic Injection Molding
Integral Manufacturing has been a recognized contract manufacturer providing high-quality, customer-specific services since 1987. Our firms — WTTM, West Troy, and RK Metals — have additional manufacturing capabilities that enable us to address a wide range of client needs, particularly plastic injection molding.
Contact us today, and we will be happy to assist you with your custom plastic injection molding needs!