ABS PMMA Plastic Injection Molding Service For Medical Parts

Plastic Injection Molding Service For Low Volume Manufacturing Medical Parts

Overview of Injection Molding:

Injection moulding enables complex shapes to be mass-produced with a high level of efficiency and manageable costs. A wide selection of materials allows engineers to exactly match the physical properties they require for any given product. Additionally, the application of multi-shot moulding techniques allows one to secure an appealing visual appearance, as well as incorporating additional functionality to the final product using materials that give high mechanical properties. 

Injection Moulding is highly repeatable; this means that all the parts that are produced will be identical, which is especially convenient for brand consistency and part reliability in high volume production.

Injection Moulding Process:

Plastic injection moulding allows to produce large numbers of parts with great accuracy and A quick cycle times from multi-cavity tools. The  process of injection mould involves a certain amount of polymer materials being heated, melted, and injected into a mould under high pressure. Further into the process, main units of the injection moulding machine are:

1. feed hopper;
2. heated barrel;
3. crew (known as the injection unit);
4. clamp unit (which holds the mould together under the injection pressures);
5. ejection unit (which removes the part from the mould).

Plastic Material Comparison Chart

The moulding process could be described by the following steps:

1. Thermoplastic granules are prepared according to the manufacturer’s guidelines. In some cases,

this may mean that the material is dried in a desiccant dryer to remove moisture.

The material enters the throat of the barrel via the hopper. The plastic granules are collected

by the helix of the rotating screw — the feeding zone of the screw;

2. The barrel is heated along its length using heater bands. There are a number of zones depending

on the machine size. The zones have different temperatures along the length of the barrel.

The temperatures are set in conjunction with the material supplier’s specification sheet;

3. The screw rotates, which moves the material forward with the pressure and determined rotational

speed towards the compression zone. This zone of the screw is designed to put a shear heat into the plastic

and to push the material against the barrel wall, giving it a consistent melt. As the material is pushed through,

it enters the metering zone of the screw and fills the front of the barrel;

4. Once the material is injected via the nozzle at the end of the barrel, it enters the runner system of the mould tool;

5. The runner system allows the material to flow through a gate into the cavity of the mould tool, which forms the shape of

the finished product;

6. The mould tool is held at a constant temperature, which, again, is defined by the material’s specification sheet.

Keeping the tool at a constant temperature allows heat to be drawn from the plastic until it reaches its heat deflection

temperature (HDT). The HDT is also defined via the material’s specification sheet;

7. Once the parts have reached the HDT, they will remain in a solid state. The mould tool can be opened;

8. Once ejected, the components fall into a boss. Parts also could be collected from the mould via a robot or a conveyor belt;

The tool closes and the whole process repeats.

Amorphous vs Semi-crystalline Thermoplastics:

There are two types of thermoplastic materials that we commonly use at Integrated Molding Solutions,

amorphous and semicrystalline. Amorphous thermoplastic material can be highly transparent and

has good formability with a lower melting temperature range. While amorphous thermoplastics have

poor chemical resistance, this provides an easier bond to other materials using adhesives or solvents.

On the other hand, semicrystalline thermoplastic material has great fatigue and stress cracking

resistance making it the perfect material for bearing and wear. However, semicrystalline thermoplastic

material can have high chemical resistance and difficulty bonding to other parts using adhesives or solvents.

Amorphous and Semi-crystalline thermoplastic material comparison chart:

When comparing plastic materials, use this plastic materials comparison chart to identify which injection molding materials

will meet the product specifications. One of the many benefits of working with a professional plastic fabrication company

is their knowledge of plastic material alloys, fillers, and additives. Custom plastic injection molding materials can be engineered

to meet required product properties that common plastic molding materials cannot.

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Plastic Injection Molding Service For Low Volume Manufacturing Medical Parts,JYH is your best injection mold supplier!

Injection Moulding is highly repeatable; this means that all the parts that are produced will be identical,

which is especially convenient for brand consistency and part reliability in high volume production.