Plastic Injection Molding
Plastic injection molding has almost unlimited manufacturing possibilities. Examples of plastic injection molding can be found in a variety of industries including consumer electronics, car parts, medical devices, tools, toys, and packaging.
What Is Plastic Injection Molding?
Injection Molding Plastic
Plastic injection molding stands out for its versatility, seamlessly meeting diverse requirements based on the plastic type employed. The choice of the right plastic is pivotal, with different plastics offering unique characteristics dictated by their chemical composition.
Deciding on the suitable plastic depends on the intended application, considering factors like durability, flexibility, performance, texture, density, and color.
At Jaycon, our experts guide you through this crucial decision-making process. With an extensive inventory of over 300 plastics for injection molding, we’re well-equipped to enhance the success of your project. Connect with Jaycon for personalized assistance in selecting the ideal plastic for your next venture.
Plastic Injection Molding Processing
Jaycon’s plastic injection molding process involves several key steps:
A detailed design of the plastic part is created, often using computer-aided design (CAD) software. This design is then used to create the mold.
The mold, typically made of steel or aluminum, is precision-machined to create the desired shape of the final plastic part. The mold consists of two halves, the cavity and the core, and may include additional features such as cooling channels.
Plastic pellets or granules are fed into the injection molding machine's hopper, where they are heated and melted. The molten plastic is then injected into the mold cavity under high pressure.
After injection, the plastic inside the mold is allowed to cool and solidify, taking the shape of the mold.
Once the plastic has solidified, the mold opens, and the finished part is ejected. This process can be automated for high-volume production.
The produced parts undergo quality control checks to ensure they meet the specified tolerances and quality standards.
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Frequently Asked Questions
These frequently asked questions can help better understand Jaycon’s expertise, processes, and approach to confidentiality.
Injection molding is becoming more environmentally friendly as machinery becomes more efficient and materials such as thermosetting polymers are capable of withstanding extreme temperatures and conditions.
Although there is some material waste with injection molding it is less than with many other manufacturing processes. Of course, the exact materials used also have a bearing on the environment in relation to how long they last, if they can come from recycled materials and how they are disposed of.
There are also considerations around the carbon footprint of the lifetime of the products that are created, including during manufacture.
Advancements in modern injection molding machinery mean that they now use between 20 and 50% less energy as compared to ten years ago.
Molding costs correlate with the number of cavities in a mold. Fewer cavities require less tooling work, which lowers the manufacturing costs to create an injection mold. The complexity of a part’s design also impact the cost, including factors such as surface finishing, tolerance, threads, detailing and the number of undercuts. Added details such as these will increase the cost, as they require more tooling.
The most cost-effective type of injection molding is rubber injection molding, which produces a high yield of durable products. In addition, consistent vulcanization processes with precise temperature controls can lower costs by reducing waste material.
Working out the exact cost of injection molding can be done with the following formula: Mold Price = material costs + design + process and profit + VAT + try out costs + packing and shipping costs.
Of these costs, materials and parts equal around 15-30% of the total and process and profit equal 30-50%.
Bearing these factors in mind, a small single cavity injection mold costs between $1,000 and $5,000. Larger or more complex molds can cost $80,000 or more. However, on average, a typical mold costs around $12,000.
While the mold tools have a high cost, the actual injection molding production has a relatively low cost.
With over 85,000 commercial plastic material option available and 45 polymer families, there is a wealth of different plastics that can be used for injection molding. Of these, the polymers can be broadly placed into two groups; thermosets and thermoplastics.
The most common types of plastic used are high-density polyethylene (HDPE) and low-density polyethylene (LDPE). Polyethylene offers a number of advantages including high ductility levels, good tensile strength, strong impact resistance, resistance to moisture absorption, and recyclability.
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