Injection Molding Service Services

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Injection Molding Specialists
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How Much Do Injection Molding Services Cost?

How Injection Molding Works?

1. Material Preparation

The first step in injection molding involves preparing the raw material:

  • Plastic pellets (also called resin) are loaded into a hopper.
  • These pellets can be made from various types of polymers, such as polypropylene, polyethylene, or polystyrene.
  • Additives like colorants or reinforcing agents may be mixed with the pellets.
2. Melting the Plastic

Once the material is loaded, it needs to be melted:

  • The pellets are fed into a heated barrel.
  • Inside the barrel is a large screw that rotates.
  • As the screw rotates, it moves the pellets forward.
  • The combination of heat from the barrel and friction from the screw melts the plastic.
3. Injection

After the plastic is fully melted, it’s ready for injection:

  • The molten plastic is forced into a mold cavity under high pressure.
  • This injection is typically done very quickly, often in less than a second.
  • The pressure can range from 10,000 to 30,000 psi, depending on the part being made.
4. Dwelling

Once the mold is filled, there’s a brief pause called the dwelling phase:

  • Additional pressure is maintained to ensure all mold cavities are filled.
  • This helps compensate for material shrinkage as it begins to cool.
5. Cooling

The cooling phase is crucial for part quality:

  • The molten plastic begins to cool and solidify as soon as it touches the mold.
  • Cooling channels in the mold circulate water or another coolant to speed up this process.
  • The cooling time depends on factors like part thickness and material properties.
6. Mold Opening and Ejection

After the part has cooled sufficiently:

  • The mold opens.
  • Ejector pins push the finished part out of the mold.
  • In some cases, robots or human operators remove the part.
7. Resetting

The final step prepares the machine for the next cycle:

  • The mold closes.
  • The screw retracts, allowing more plastic pellets to fall in front of it.
  • The process then repeats from step 2.

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Applications of Injection Molding

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FAQ's

What is Injection Molding?

Injection molding is a manufacturing process that mass-produces thousands of identical plastic components. It involves injecting the molten material (usually thermoplastic and thermosetting polymers) into a mold fitted into the machine.

These molds are precision-machined to match the shape of the final product. They also have cooling lines that reduce the solidification time by circulating water or oil from an external temperature controller after material injection.

Besides plastics, the process can make metal (die-casting), glass, confections, and elastomer parts, which can also be utilized by PCB manufacturing companies for creating various electronic components.