If the operator opens the gate too soon and the product is ejected before the material incurred proper and even cooling time, the operator has shortened the process cycle. An inconsistent process cycle can lead to uncontrolled shrinkage rates, which then causes mold warping. Discover how our forensic research can help identify and solve your product failure challenges by requesting a quote today. Request a QuoteRequest quote Plastic Molded Concepts is a U.S based company that uniquely specializes in molding with engineered resins. We’ve helped dozens of companies resolve issues they were having with an injection molding supplier. Check out our case study to see how we helped resolve a part self-destruction issue for a military and aerospace hardware manufacturing company. When people think of factory jobs in Milwaukee, what usually comes to mind is a place that pays poorly and has no room for professional growth. PMC is not one of those places!

How To Calculate Injection Molding Tonnage

Gate location can affect a variety of critical factors, including:Polymer molecule orientationOverall strength & structure of the partPart shrinkageMold warpageAbility to hold a required roundness or flatnessOperational considerations, such as injection pressureAesthetics, such as injection molding gate marks, sink marks, voids and flow lines Depending on part requirements, you may need post-molding services, such as:Heat treatingSurface finishingWeldingUltra-Sonic WeldingAgency Approval(s) In fact, it’s often the case that the cycle process is not the problem; but without in-depth training on scientific plastic injection molding, these operators have little other choice but to continue manipulating the process in hopes of creating a workable solution. Cavity pressure is directly related to part dimension. The variation of cavity pressure will vary the dimension in a part.  The less the variation, the tighter the dimensional control or variation.  The higher the cavity pressure value gets the less the part will shrink, all other values remaining the same.  One rule of shrink to remember is that plastic shrinks less in the direction of plastic flow and more perpendicular to flow.  A common error in this process is when molders experiment with machine settings in order to determine when the gate freezes. At this point, a defect occurs in the parts and then reverses that move until the defect goes away. The problem with this is that the other 3 processes are going to interfere with the finished part properties in ways the molder cannot see. This mistake not only costs manufacturers money but costs customers when they find out their new plastic part does not seem to last very long in its intended use.Cooling and Injection Rates Please note, we make components for medical devices – not end-use medical products. For more information regarding FDA requirements, please click here.

What Is Injected Molded Plastics

In fact, this is more true now than ever before with advances in engineered resins making it possible for plastic to perform as well as (or even outperform!) metal in aspects like strength-to-weight and strength-to-stiffness ratios. Castings are always stronger & less prone to stress fracturing. A part machined out of cast material will often give you a resulting stronger part. If machining the part includes sharp corners, this could become a trap into the material selection being completely wrong for the molding process.Size Insert Molding is when plastic is injected into the mold cavity and insert piece (or pieces) prior to plastic injection molding. The resulting product is a single piece with the insert encapsulated by the plastic.Insert Molding Benefits:Faster Assembly TimeReduced Part SizeReduced Part WeightCost-EffectiveInsert Molding Product Examples:Filters with Fine Mesh InsertsVacuum Hose ConnectorsAutomobile Air DuctsHeavy Equipment ComponentsMedical Syringes*Special Notes: Below are the top 5 reasons why manufacturers are now choosing plastic gears over metal. Master Molders have completed rigorous, certified training programs in scientific plastic injection molding.