Why do we need to have the correct injection molding tooling?
The cavity design of the plastic injection mould and injection molding tooling is very important because that is responsible for the final shape of the product. Apart from the cavity design, there are different types of injection moulding tools that play a crucial role in the final formation of the product.
If you happen to set the plastic material moulding process at a wrong speed, there is a high possibility for stress and distortion to take place. One must select the correct injection molding process step by step in order to get the perfect shape every time.
Lets learn more about injection molding tools:
Keeping the cooling down rate of the material in mind, the process of moulding must be initiated. Certain plastic materials have to be moulded in water cooled tools.
In this article we have shared injection moulding product list along with their functions so that you can get a basic idea of what has to be done during the process-
Here are the Main tools that are part of Injection molding tools:
- Moving half back plate
This particular injection molding tool is fitted in the moving pattern of the injection molding machine. It provides the basic structure for the cavity. After opening the same, one can eject the molded part.
- Locating ring : This fits in a location hole on the fixed half platen of the injection moulding machine to ensure correct alignment of the tool and the machine.
- Risers: These will provide the space for the ejector plate to move freely.
Yet another important injection molding tool remains important is the locating ring that is fitted in the location held on the fixed half platen of the injection molding machine. In order to assure the correct alignment of the machine and the tool, a locating ring is used.
- Guide pins
- Sprue : This is the entry point where the plastic material is first injected into the cavity.
Correct formation of the product takes place with the guide pins that bring the two halves of the tool together.
- Core retaining plate
You can mount the core retaining plate on the top of the machine
- Ejector locating plate and ejector plate retainer
The overall process is made more manageable with the digital locating plate and ejector plate retainer.
- Mould Cavity : The core plate used to create a cavity through the gap that will be filled with the plastic material.It forms the plastic component.
- Mold Core Plate: It holds the core insert in place and acts as a “stiffener”. It is usually made of mild steel.
Injection molding process step by step guide –
- Step 1 – manufacturing and feasibility
During the first step, lab technicians assure the product specifications and then create a team that determines the potential problems who tries to eliminate the same by choosing the correct injection mold tooling methods. The first step makes sure that the selected Idea is feasible and practical or not.
- Step 2 – design
After the preliminary research is executed, the second step includes the creation of 2D or 3D designs that determine the injection molding defects and its a great learning for injection molding for dummies as initial start. The next step is finalized after the cognitive idea is confirmed
- Step 3 – final design specification
Injection molding design is given to the tool builder for mold construction. The final modifications are executed with special attention in order to eliminate the possible injection molding defects.
- Step 4 – construction for injection moulding tools
The primary and secondary tools for injection molding are constructed, reviewed and verified. The progress is closely monitored and meetings are held to inspect whether the final outcome is desirable or not.
- Step 5 – checking out the initial sample of the tool in house
Right after the basics of the moulding process are executed, the same is presented in the manufacturing department for the final approval. The sampling is scientifically tested and accurately determined.
- Step 6 – making final corrections
Injection molding machine parts and functions are analyzed by the experts to remove injection molding defects. The process of verification is documented and kept carefully. It is only after the final approval that the final production takes place so that the customers can obtain the product.
Types of Injection moulding materials used-
Maximum of the injection molding tooling are produced using the hardened pre hardened Steel. Hardened steel is heat treated with a specific machining process. It receives a better resistance in comparison to the pre hardened Steel. Also, it lasts longer.
As compared to Aluminum, Steel based moulds are more durable and support a higher production rate.
Most of the design experts use aluminum as the injection molding tooling product. Aluminum has reduced time for building and is quite easy to machine in comparison to Steel. The turnaround cycles are faster in case of aluminum. However, Aluminum is softer than steel and even if you harden the same, it is still difficult to maintain. The rapid wearing of aluminum material is the main drawback of it.
- Copper alloy
Aluminum is not a perfect choice when it comes to creating Complex parts aur glass filled plastics. It quickly wears away which induces the cost of production. As a result, experts prefer using copper alloys as a replacement for aluminum.
In order to improve the wear resistance, both aluminum and Steel can be heat treated and hardened.
As A final advice, choose the correct Injection molding tooling product in order to reduce the overall manufacturing cost. After all, the ultimate choices to receive higher returns and better customer satisfaction.