塑料注射成型– A Beginner's Guide

Ever wondered howmass production单位每次都精确地生产数十万个相同部分的零件？通过一种称为塑料注塑成型的技术使其成为可能。您使用的所有这些塑料盖，电话盒，键盘都是由某种类型的塑料注塑制造制造的。由于其高效率和准确性，塑料注塑成型是现代工业生产技术的重要组成部分之一。如果您已经对所有这些组件（无论是大小）都感到好奇，这些组件是如何由数百万美元的绝对准确性制造的，那么技术的复杂性将使您更加捕捉。让我们进一步了解该技术的工作原理。

History of plastic injection molding

1872年，一位名为John Wesley Hyatt的美国发明家为制造塑料台球而不是象牙色的塑料球申请了这项技术专利。他的产品并没有成功，但最终他的技术做到了。从那时起，技术已经飞涨。最初，它被用来生产简单的塑料设备，例如球和纽扣。如今，相同的技术为从药物到汽车再到电子产品的所有领域提供了动力。如果不存在这项技术，很难想象我们每天都以同样的方式看到我们周围的事物。在深入研究这种方法以及如何变得如此流行和有效之前，让我们看看塑料注射成型的工作原理。

什么是塑料注塑成型？

The basic mechanism of the technology is rather simple. At first, the machine injects molten plastic into a metal mold. Inside the mold, the liquid plastic eventually cools and hardens. Once the plastic is no longer molten, the metal mold separates into two, revealing the finished plastic product inside.

Despite this simplicity in the fundamental process, this technology is highly efficient. The probability of error is minimal. Manufacturers and industrialists around the globe rely on injection molding to produce quality goods with consistency.

For a more detailed understanding, let’s see how this injection machine works.

The machine is made up of four main parts: an injection unit, a clamping unit, the control, and the base. To start the process, a barrel containing an internal screw-shaped device is fed with small plastic pellets. The screw-shaped device, known as the auger, feeds the plastic to the barrel by rotating the plastic at a high force. The body of the barrel is fitted with heater bands, which effectively melts the plastic.

The mold closes once the machine cycle starts. Then the auger injects molten plastic in high pressure into the empty space of the mold, called the cavity. It just takes a few seconds to do this. There are coolants present around the mold to speed up the process of solidifying molten plastic. In as little as 60 seconds, the molten plastic obtains the desired shape.

Then the mold opens and the plastic structure is ejected. In just a minute or so, the machine successfully produces one unit of the product and is ready to go again.

为什么使用塑料注塑？

The technology of injecting plastic into a mold is used in every industry to some extent. That leads us to the question of why it got so popular in the first place.

One of the major reasons is the technology’s efficiency. When units can be produced in under 60 seconds, a few hours of application of the machine yields hundreds of units of the product. As more and more units are produced, the initial cost of setting up the machine is met in a very short time. After that point, the profit generation goes up by leaps and bounds. While saving time and money are the primary reasons this technology has garnered widespread popularity and dependency, there are some other reasons as well.

Low scrap rates: A traditionalCNC machining将切断了一块巨大的原始塑料sheet or block fed to it. That leads to the problem of growing scrap rates. All of that waste plastic has to be recycled, reused, or disposed of. Any of these options incur an additional cost, apart from the manufacturing cost itself. Injection mold machines do a great job at reducing scrap. It would in turn save money that would otherwise be spent on proper management of the scrap. Wastage occurs in these machines only in case of malfunction or defects. The gate location, sprue and runners of the machines do produce some scrap, but it is considerably less than what CNC machining would do. Sometimes there is also loss due to leakage from the metal mold’s cavity. Technologies like 3D printing, however, produce even less (or none) scrap.

废料还取决于用于生产的塑料材料。一旦由于暴露于空气而固化，像环氧树脂这样的热固性材料将再次熔化。任何融化它们的尝试都会导致塑料燃烧。由于这个原因，热固材料废料不适合回收或重复使用。

Thermoplastic material, on the other hand, can be recycled and reused. It can be molten again even after it has already been melted and solidified before. Often this recycling takes place within the factory. By scraping waste out of the sprues and runners and injecting it back to the machine, wastage is reduced to a great degree. The recycled material is termed re-grind. It is generally of inferior quality than the plastic that has not been reused. Regrind material is generally used for those units that do not require high-quality, robust material. One production unit can also accumulate a substantial amount of regrind and sell to some other unit that produces goods with inferior material. Overall, plastic injection moulding does a better job than other production technologies in terms of time, money, andresource management.

Complex designs: Many complex designs can be produced without any secondary operation in a molding machine. It is achieved by using unscrewing features and core pulls. By eliminating the need for secondary operations, you can save money on the overall production cost. The designs can be parts with threads and side holes, and the molding machine will deliver the exact same product, finished with all the complexities, right out of the machine.

Different finishes: Whether your product needs a smooth finish or a rough one, it can be easily done in an injection molding machine. By default, most machines produce products that have a very smooth finish. The good news is that you can alter the type of finish you desire without any additional operation. These machines also have the ability to produce unique finishes, like engravings or patterns. No matter what type of finish you want: shiny, rough, matte, it can all be done in the same machine, with the same efficiency and accuracy.

Repeatability: Plastic injection molding machines can repeat the production of the same unit as many times as you want. That translates to having your second product identical to your first one, and the third identical to the second, and so on. Every business owner is concerned about brand image and consistency. Injection molding machines take care of that concern with this feature of repeatability. With all products made identical, there is little chance of faulty products going out to the consumers.

控制颜色：注塑机可以将您想要的任何颜色注入产品。甚至可以在单个产品中获得两种或更多颜色。您可以使用两射或过度耗尽技术来实现这一目标。对于针对儿童的塑料产品，例如玩具，可以控制颜色，这在很大程度上决定了产品的成功。

塑料注塑机的成本

Getting a perfect design before your machine starts production is very important. A faulty design will result in huge losses and unsatisfactory products. That is the main aspect of injection molding which needs a big investment. Designing and prototyping the part and the mold tool incurs a heavy cost. The Return of Investment, however, covers up for the cost if the prototypes are designed to perfection. Designing the tools and the prototypes requires a considerable amount of time and money, and that keeps some manufacturers away from using these machines. Owing to the complexity of some of these designs, only experienced engineers can manufacture them. Cost of hiring skilled technicians increases in this scenario. If this one time investment is not a hindrance, an injection molding machine makes up for the investment in a very short time.

The average cost of these projects is generally $1,000-$20,000. The ROI also depends on the size of the manufacturing unit. The scale of the production unit and revenue are directly proportional. With a high scale of production, the cost of the machine is covered up in a short time. With low scale production, the time needed increases. The complexity of the design, material used, part size and quantities of production are the factors upon which the initial cost of setting up the machine depends.

To conclude this brief guide on plastic injection molding, we can safely say that it is one of the breakthrough technologies of our generation. It has enabled the mass production of quality goods on an unprecedented scale. Every field of production employs this technology to get their work done effectively and efficiently. So if you are a manufacturer or industrialist wondering how to take your business to the next level, setting up a plastic molding machine is a safe and reliable option. With the development in all fields of technology, it can also be safely assumed that plastic molding machines will only get better and even more efficient with time.

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