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Visual Encyclopedia of Chemical Engineering Injection Molding
Visual Encyclopedia of Chemical Engineering Injection Molding
Injection Molding
Injection molding is the most common molding process after extruders. It is widely used
to process thermoplastics and thermosets. There are two types of injection molding
machines: injection molding machines, and reaction injection molding machines.
Injection Molding
The first injection molding machine was patented by John Wesley Hyatt in 1872. It was a
stuffing machine that consisted of a steam-heated chamber and a hydraulically operated
plunger. In injection molding today, the molding material is first heat-softened, injected
into a mold, then cooled to form the desired product. Injection molding machines are
typically categorized as either vertical or horizontal.
General Information
The first type of a commercialized injection machine was the single stage plunger , fol-
lowed by preplasticizing machines . Today, single screw injection molding machines are
the industry's choice. In addition, multi-station machines are used to produce multi-color
products.
(Copyright Milacron, Batavia, OH)
The polymer enters through the hopper into the screw area, where it is heat softened. A
screw forces the polymer into the mold. After the polymer is cooled, the molded product
is ejected and the process can begin again.
Equipment Design
The picture below show s a clamping mechanism in a horizontal machine. In this type of
injection molding machine, both the clamping and the injection units are horizontal,
making access easier. This style is preferred when an automated system is desired or if
regular maintenance and mold adjustments are needed.
The picture below shows a clamp ing element of a verticle molding machine that oper-
ates in a similar fashion as the horizontal molding machine. Both the clamping and injec-
tion units are vertical. This machine setup is preferred when space needs to be preserved
or a relatively heavy or large mold needs to be used.
(Copyright Milacron, Batavia, OH)
Usage Examples
Injection molding machines may be used to make almost anything out of plastic. The
only exceptions are bottles and other containers, which are manufactured using blow
molding. Products can range in size from small handheld containers to car bumpers.
(Copyright Master Molded Products Corp., Elgin, IL)
Other examples of products that can be made using injection molding are plastic beach
chairs and all-terrain vehicle components.
(Copyright Milacron, Batavia, OH)
Advantages
Disadvantages
Acknowledgements
Bayer MaterialScience AG , Fribourg, Switzerland
EPW , Elkhart, IN
Milacron , Batavia, OH
References
Chanda, Manas and Salil K. Roy. Plastics Technology Handbook , 3rd ed. New York: Mar-
cel Dekker, Inc., 1998, 262-268. Print.
Kamal, Musa R., Avraam I. Isayev, and Shih-Jung Liu. Injection Molding: Technology and
Fundamentals. Munich: Hanser, 2009. Print.
Rubin, Irvin I. Injection Molding Theory and Practice . New York: John Wiley & Sons, Inc.
1972. 3-20, 63-74. Print.
Whelan, A. Injection Molding Machines . Elsevier Applied Science Publishers Ltd., 1984.
95- 104, 289. Print.
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