Design for Injection
Haolia Rahman, PhD
What Is Injection Moulding?
Injection moulding is a manufacturing process
for producing parts by injecting material into a
mould. Injection moulding can be performed
with a host of materials mainly including metals,
elastomers, confections, and most commonly
thermoplastic and thermosetting polymers.
Material for the part is fed into a heated barrel,
mixed, and forced into a mould cavity, where it
cools and hardens to the configuration of the
cavity.
Injection Moulding Resources
Material
Mould
Machine
Manpower
Injection Moulding Machine
Injection Moulding Process
Material preparation
Feeding into hopper
Injection
Mould holding and cooling
Ejection
Injection Moulding Machine Process
Material granules are fed into hopper then
melted down in barrel which is surrounded by
the heaters.
Injection Moulding Machine Process
Melted material is injected into mould cavity
and mold is held under pressure until the
material cools and hardens.
Injection Moulding Machine Process
Once the material hardens, the mold is opened
and the component is ejected by runner plate.
Injection Moulding Machine Process
And the process can be repeated.
Injection Moulding Machine Process
Mould
Moulds are the common terms used to describe the
tool used to produce components in moulding.
Moulds are constructed from hardened steel, pre-
hardened steel, aluminium, beryllium-copper alloy.
In general, steel moulds cost more to construct, but
their longer lifespan will offset the higher initial cost
over a higher number of parts made before wearing
out.
The moulds can be manufactured either by CNC
machining or by using electrical discharge machining
processes.
Mould Design
The mould consists of two primary components, the
injection mould (A plate) and the ejector mould (B plate).
Molds Construction
Product Design
Mould Cooling
Constant mold temperature for uniform quality
Reduced cycle time for productivity
Improved surface finish without defects
Long mold life
Avoiding warpage by
uniform mold surface
temperature (warpage
caused by nonuniform
cooling)
Mould Cooling
Moulding Defects
1. Blister
Blisters can be defined as raised defects on the
surface of a molded part caused by trapped gases
in the part that could not escape before the
surface began to ``skin'' during the molding
process.
2. Flash
It also called Burrs and may caused by tool
damaging, excess material injecting, too high
injection speed or low clamping force. Dirt and
contaminants around tooling surfaces may also
cause this defect. And this defect usually
demonstrates as excess material in thin layer
exceeding normal part geometry.
Moulding Defects
3. Burn marks
When tool lacks venting or injection
speed is too high, plastic parts may have
black or brown burnt areas located at
furthest points from gate.
Moulding Defects
4. Warping
This defect may lead parts distorted. The
cooling is too short, while material is too hot, it
has not enough time to cooling around the
tool, and has incorrect water temperatures.
The parts bow inwards towards the hot side of
the tool.
5. Voids
During the holding time, if injection molding
lack of holding pressure to pack out the part, it
will has empty space within part. Voids also
happens because the mold may be out of
registration, when the two halves don’t center
properly and part walls are not the same
thickness.
Moulding Defects
5. Embedded contaminates
During the process of plastic molding, foreign
particle may embed in the part. This defect is
commonly caused by particles on the tool
surface, contaminated material or foreign
debris in the barrel, or too much shear heat
burning the material prior to injection.
6. Short shot
It happens when plastic parts are lack of
material or injection speed or pressure too
low. Finally, the plastic parts can not be made
completely.
Manpower
To set up process
To monitor process and troubleshoot
To operate machine
Apllication of Injection Moulding
Plastic Injection Moulding
Rubber injection Moulding
Metal Injection Moulding
Plastic Injection Moulding
It is a manufacturing process for producing
components by injecting polymer material into
a mould.
Thermoplastic and Thermosetting plastic
material are used.
Thermoplastic materials are reusable.
Plastic Injection Moulding
Plastic Injection Moulding Applications
Writing instruments components ( pen barrel,
cap, bush etc)
Computer Electronics
Automative Components
Aerospace Components
Electronic Components
Toys etc.
Rubber Injection Moulding
Injection molds can make many rubber
components. It makes valve steam seals, oil
seals for engines, telecommunication items
etc.
Metal injection moulding
• Injection molds can stamp out small to large items.
It can stamp out automobile parts from spark plugs
and floor pans to ball bearings. It also can stamp
out items like TV hangers and knitting needles.
Advantages Of Injection Moulding
Fast production.
Low labour costs.
Design flexibility.
High-output production.
Multiple materials can be used at the same time.
Can be used to produce very small parts.
Leaves little post-production scrap.
Ability to include inserts.
Good colour control.
Good product consistency.
Reduced requirements for finishing.
Good dimensional control.
Disadvantages Of Injection Moulding
High initial tooling and machinery cost.
Part design restrictions.
Small runs of parts can be costly
Molding Machine Size
Determination of the appropriate size of an injection molding
machine is primarily based on the required clamp force. This
in turn depends upon the projected area of the cavities in
the mold and the pressure in the mold during mold filling
Molding Machine Size
Molding Machine Size
Molding Machine Size
Injection Moulding Machine Process
(Cycle Time)
Injection Moulding Machine Process
(Cycle Time)
• Injection Time
Pj = injection power, W
pj = recommended injection pressure, N/m2
Vs = required shot size, m3
• Cooling Time
hmax = maximum wall thickness, mm
Tx = recommended part ejection temperature, °C
Tm = recommended mold tempeature, °C
Ti = polymer injection temperature, °C
α = thermal diffusivity coefficient, mm2 /s.
• Mold Resetting
Td =the dry cycle time
Injection Moulding Machine Process
(Cycle Time)
Mold Cost Estimation
Mold base Costs
Mold base Costs
