INJECTION MOLDING

In injection molding, material is fed through a hopper into a barrel where a reciprocating screw mixes and melts the material then injects it into a mold.

Know Your Options in Injection Machine Nozzles

Improvements in nozzle design in recent years overcome some of the limitations of previous filter, mixing, and shut-off nozzles.

Injection Molding: Essential Reading

Time to Swap Out Those General-Purpose Injection Nozzle Tips

Still the standard in the industry, GP nozzle tips can cause a myriad of problems for molders. There are alternatives out there that should be examined.

How to Achieve Simulation Success, Part 1: Model Accuracy and Mesh Decisions

Molding simulation software is a powerful tool, but what you get out of it depends very much on your initial inputs. Follow these tips to create the most successful simulation possible.

How Backpressure Optimization Affects Melt Preparation

Backpressure is often the least understood of the settings in an injection molding process, even though it can play a significant role in the final quality of the part. Let’s start with understanding what backpressure is and then learn how to optimize it for a given mold.

How to Reduce Sinks in Injection Molding

Modifications to the common core pin can be a simple solution, but don’t expect all resins to behave the same. Gas assist is also worth a try.

21 Tips to Slash Energy Costs in Molding

This checklist can provide injection molders a good starting point on the path to reduced energy consumption and can generate some money savings on that journey.  

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FAQ: Injection Molding

Plastic injection molding is a cyclical manufacturing process that allows for cost-efficient production of a mass number of identical parts made from either thermoplastic or thermoset materials.

Cushion values in injection molding ultimately are an indication of a part’s quality, especially its dimensions. A consistent cushion will create consistent part dimensions. 

It is important to determine which type of bubble your part has, and what the root cause might be. Determining bubble type will allow you to pinpoint the source and determine your next course of action to eliminate the problem.

 

 

Most molders are still relying on “general-purpose” screw designs that go back 30 years. With all of the technical improvements that have been made on machines over that time, nothing has been done to improve melt uniformity. We still use “general-purpose” (GP) screws, which well-known screw designer Bob Dray wisely has called “no-purpose” screws. That is they do not melt plastic uniformly. Processing with a uniformly melted plastic would seem like a high priority, but it has seen little if any attention.

 

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