Injection moulding can be performed with a variety of materials, including glasses, metals, elastomers, confections and, most commonly, thermosetting and thermoplastic polymers. This process can be used in various circumstances, particularly when producing: large shot weights, high volumes of small to medium size parts, incorporating bonded inserts, achieving close dimensional tolerances and making components that require uniformity or consistency of colour. Some examples of where Injection moulding components are used include: coloured instrument boots, O Rings, drive coupling assemblies and automotive parts.
What are the advantages of injection moulding?
Lower unit costs – Injection mouldings often have a low production cost per unit, due to reduced cycle times and higher levels of automation.
Faster cycle times – With Injection moulding, cycle times are approximately between 15-30 seconds for each cycle. This type of moulding can produce a vast amount of parts per hour depending on how many impressions are in your tool.
High dimensional tolerances – Close tolerances on smaller, more intricate parts is possible when using the Injection moulding process. The greater level of automation also allows for a much higher degree of consistency of part.
Low levels of flash – The injection press’ clamping force keeps the mould tightly sealed closed during the cycle, thus this leads to maintaining tighter tolerances and lower levels of flash. Since the process does not depend so much on overfilling the mould to make good parts, there is less variation across the split line of the part, and thus less flash.
Little scrap/waste – If thermoplastic material is used in this process, excess material or scrap can be ground up and recycled so that it can be reused, rather than wasted. This is not always the case with thermoset materials, however.
Reduced need for secondary trimming work – There is often very little secondary, post-production work needed due to the parts usually having a good finished look upon ejection.