Thermoplastic Injection

Molding
An Overview

Injection Molding
Topics to be Covered
Introduction
Part Design
Tooling Design
Machine

Plastics
Thermoplastic
Can be remelted to become viscous fluids
and can then be cooled to a solid state to give
the same properties as before melting.

Thermosetting
Cannot be remelted after formation

Plastics
Thermoplastic
Most common. Can be fabricated by blow
and injection molding, vacuum forming,
extrusion and other methods.

Thermosetting
Can be injection molded or resin transfer
molded (RTM). Can be laminated or bag
molded or fabricated using lay-up methods.

Why Injection Molding?

High production rates

Large volume production possible
Low labor cost per unit
Little or no post-processing required
Many colors and finishes available
Good for many complex shapes
Good for small parts
Minimal scrap
Close tolerances can be maintained
Insert molding possible

Why Not Injection Molding?

Machine costs are high

Mold costs are high
Process control issues
Part design issues

Part Design
Constant Wall Thickness
Nonuniform cooling leads to problems of
voids, warpage and sink

Radius Corners
Improves plastic flow
Reduce stress concentration

Draft Angles
Slight angle on walls perpendicular to parting
line

Part Design
Shrinkage
Amount part will reduce in size as it cools to
room temperature
Plastic dependent

Tooling Design

Mold Plates
Ear Plates
Ejector Pin Plates
Mold Pins
Sprue
Runner
Gate
Vent

Machine
Process Cycle
Polymer pellets fed into cylinder
Plasticate in cylinder
Inject polymer into mold
Cool part
Eject part

Machine
What happens in barrel?
Conveying
Compaction
Melt film formation
Melt pool formation
Melting complete

Machine
Process Parameters
Screw speed
Injection speed
Injection pressure
Back pressure
Shot size
Barrel temperature
Mold temperature
Cooling time

Machine
Projected Area Press Capacity
Includes mold cavity and runner system
2 to 2.5 tons per square inch of projected area