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What issues should be considered in injection molding production?

If you want to be in the mass production section you want to make sure you get the right design for the first time. This is much more complicated than you think. Potential negative injection molding includes the following.

The high cost of injection molding and large required delivery

The tool itself is almost a project, a stage of the entire injection molding process. To be able to produce an injection molded part that must first be designed and prototyped (possibly by CNC or 3D printing), then you must design and prototype the mold tool that can produce part of the replica volume.

Finally, you can usually produce injection molds after the two stages of extensive testing described above. As you can imagine, all the iterations require time and money before the tools can be mass-produced correctly. It is a rare prototype injection mold. Although it does occur, it is part of the multi-cavity tool. For example, suppose we want a new shampoo cap injection mold. The cap may have threads attaching it to the bottle, a living hinge that closes in advance and maybe some injection over molding. The company can choose a cavity tool to ensure that all features will be mold as needed. Approved, they will use a new tool that can shape, for example, 16 hats. They do single-cavity tools first. If there are any problems, they don't need to pay. Waiting for it is 16 times that of each cavity.

injection mold

Tools are usually made of steel (a hard material) or aluminum is difficult to change

1. If you want to add plastic you can make part of the tool cavity pass through cut steel or aluminum
But if you want to take away you need to reduce the size of the plastic tool cavity by adding aluminum or metal. This is extremely difficult, and in many cases, it may mean that you need to abandon part of this tool (or tool) and start over. In other cases, you can weld metal cavities that are undesirable.
injection mold venting

2. Injection molding requires the uniform wall thickness
If you cut the above Panasonic mold you will notice that the wall thickness is about 2 - 3 mm thick. It is important to prevent the wall from becoming too thick to prevent inconsistencies caused by the cooling process. Defects are like shrink marks. A good rule of thumb is to keep the wall less than or equal to 4 mm thick. The thicker wall materials are used, the longer the cycle time will be and the higher the cost of each part of you. Conversely, if the wall thickness is thinner than 1 mm or you may experience trouble filling tooling (causing gaps or short shots). Designers can compensate for this potential by using a material with a higher melt flow index Nylon This is usually suitable for thin walls such as 0.5 mm. Different manufacturing technologies like CNC do not require a uniform wall thickness.

Most areas cannot be produced as a single block by injection molding

Due to the size of the injection molds, the machine and mold tools themselves are limited. For example, the large injection molding part considers the target shopping cart. Although there are very large parts of the molding machinery (such as 1000 tons of trains on the size of the train), using it is very expensive. For this reason, the function of creating an injection molding machine than a typical object is usually in multiple pieces. CNC machines also have similar restrictions on product size and more restrictions on 3 d printing. CNC is a limited travel and size bed in milling machines, and large 3D printing sections usually need to be printed on multiple pieces and then combined together.

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