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 INTRODUCTION
• Injection moulding is one of the most commonly
used processing technologies for plastics
materials.

• INJECTION MOULDING CYCLE

• The basic injection cycle is as follows: --Mold

close - injection carriage forward - inject
plastic - metering - carriage retract - mold
open - eject part(s).
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Advantages
High production rates
• Design flexibility
• Repeatability within tolerances
• Can process a wide range of materials
• Relatively low labor
• Little to no finishing of parts
• Minimum scrap losses

Disadvantages
High initial equipment investment
• High startup and running costs possible
• Part must be Designed for effective molding
• Accurate cost prediction for molding job is difficult
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 Types of Injection Units
• Single Stage Plunger unit

• Two Stage Plunger Unit

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• Single Stage Screw Unit

• Inline reciprocating screw unit

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 ADVANCED TECHNIQUES
• Gas Assisted Moulding
• Gas assisted moulding has been commercial now for
a number of years. There are several approaches to
the process technique which has many benefits to
offer.
• This is achieved by injecting a gas into a tool cavity
partially filled with resin, while the resin injection
continues to prevent a hesitation of the flow front.
After the resin injection is completed, the gas
injection continues, forming a gas bubble that keeps
the resin flow front moving until the resin skin
reaches the end of the mold.

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Process Limitations
• There are two basic processes in gas assisted
moulding:-
1. Filling the mould using gas pressure
2. Packing the mould using gas pressure
Advantages
• greater design freedom (thick-walled, rod-
shaped parts possible)
• high degree of rigidity due to larger closed
cross-section profiles
• reduction of sink marks
• uniform shrinkage and thus less distortion
• shorter cycle times as compared to thick-walled
compact parts
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Water-Assisted Injection Molding
• Water-assisted injection molding is the newest way
to mold hollow or partly hollow parts. It’s
basically similar to gas-assist molding as a means
to core out thick sections. But water-injection
technology (WIT) comes with a big advantage:
direct cooling inside the part. The thermal
conductivity of water is 40 times greater than that
of gas, and water’s heat capacity is four times
greater than gas. “With the cooling capability of
WIT, cooling cycle times can be reduced to only
25% of that of gas,”

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process is somewhat similar to the gas assist process, however water is used as
the medium.  Since water is incompressible, it can produce better-shaped hollow parts
with good control and smoother surfaces.  It can also reduce the cycle time due to the
additional cooling from the water

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 Metal injection moulding
• The injection moulding of various metals has now reached the
commercial application stage this article
• Sintering
• The metal injection moulding sintering process can eliminate
or reduce machining operations and is ideally suited to the
production parts in medium to large quantities.
• Typical metals that can be processed in this way include
carbon, low alloy, steels stainless steel, tungsten, bronze,
nickel and others.

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• PROCEDURE:-
• The first stage of production involves the accurate
mixing of the carrier a wax or polymer binder
with fine spherical powdered metal particles
• next stage the compound is transferred to the
moulding machine hopper this is then injected into
the mould using the high pressure developed by
the machine process.
• After forming the parts in the injection moulding
stage they are then transferred to an oven the
mouldings at this point are called in the green
state and are still relatively brittle depending on
the binder that is used.
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 Semi Solid Metal Processing
• Material used
• Materials currently being used include AZ-91-D, AM-50A,
AM-60B, AE-42, Zamak No3 and ZA-8.
• The process uses a magnesium alloy has its feed stock which
is introduced to the machine in a ready made pellet form just
like plastic feed stock these are fed through a dosing unit into
the throat section of the machine barrel that feeds the screw
this area is protected by an argon blanket atmosphere to
prevent oxidisation occurring to the alloy.
• The shearing action of the screw and the generated heat
produced by the screw rotation along with the heating
elements
• state when the required amount of slurry as been accumulated
in front of the screw tip and non-return ring injection takes
place injecting the material at high pressure into a preheated
mould.
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• ADVANTAGES OF PROCESS
• No other post processing is required by
the part and the dimensional requirements
have been achieved without requiring any
further processing or treatments.
• include increased mechanical properties
• substantial reduction in porosity
• greater dimensional accuracy
• stability, thinner wall sections
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 Co-injection molding
• Co-injection molding is the term used to describe the
process of feeding several melts, one after the other,
into one mold during the injection molding process.
• A substrate, e.g. in the form of a fabric or film, is
inserted into the mold before the melt is injected in.
• Two-material co-injection molding / two-color co-
injection molding,
• three-color co-injection molding / three-material co-
injection molding / multi-color co-injection molding
• Multi-material molding, sandwich molding
• 3D MID (Molded Interconnect Devices)
• Back-molding of film and fabrics
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• Two-material co-injection molding
• Two-material co-injection molding we mean the
injection of two different melts into the mold, one
after the other. They may comprise the same
material in different colors or two different materials.

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• Three-color and three-material co-
injection molding
• Example- car rear lights, three or more
different components are needed.

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 Stack-Mold Technique
• It is basically a stack technique with a rotating center
section having its own hydraulic cylinder drive
system. The axis of rotation can be either horizontal
or vertical.
• The machines used in this process can be equipped
with much lower clamping forces than those for the
rotary plate technique - probably around 60 % lower,
significantly reducing investment and production
costs. The production cost for a car rear light, for
example, was just under 7 % down.
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• Advantages
• Quick mold changes
• Balanced hot runners
• Improved mold alignment
• Significantly reduced mold wear

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 MICROCELLULAR INJECTION
MOULDING
• Microcellular plastic foams can be made by
mechanically or chemically dispersing a gas,
usually carbon dioxide or nitrogen, into the
polymer melt.  A mechanical process employing
supercritical fluids for this purpose
• The benefits of microcellular foaming
include:
• Reduced weight
• Improved flowability
• Lower apparent viscosity
• Less warpage, shrinkage and molded-in stress
• Improved cycle time
•Sunday,
Reduced
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Insert Moulding or Encapsulation
• The Insert Molding and Encapsulation techniques used in
molding a wide variety of common plastic components. Insert
molding is a form of injection molding where molten plastic is
injected into the mold and surrounds or backs an insert
previously placed in the mold.

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 ELASTOMERIC MOULDING
Application

Fiber optic cable boots

Power supply gaskets

Vibration isolation mounts

Keypads

Buttons

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 CONCLUSION
• The major advance in polymer process molding
will be the inclusion of morphological
characteristics, including both changes during
the process itself and morphology of the final
part. While significant progress has been
achieved, substantial challenges remain. This
major advance is just one of the steps required
to complete the process-structure-property
connection for multiphase polymer systems.

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