The relationship an OEM maintains with its injection molder is integral to successful production of complex plastic parts. Often the partnership remains a value-add across projects and time.
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But, there are instances when alignment between OEM expectations and molder capabilities erodes either suddenly or incrementally. Regardless, the outcome is the same: it&#;s time for the OEM to shuffle suppliers and find a new injection molder.
Perhaps you find yourself in this situation. Transitioning to a new custom injection molder can be a little daunting. However, if you narrow your search to molders with broad-based experience and proficiencies you&#;ll likely find a long-term supplier that can consistently provide needed support from design through production.
Where to begin? Use the following list to qualify potential suppliers and ultimately guide the selection of your next custom injection molding partner.
Evaluating Injection Molders
Knowledge and experience are baseline criteria for consideration of a custom injection molder for complex applications. What differentiates suppliers with true partnership potential, though, is diversity:
1. Market versatility
Molders that specialize in your industry may seem like the logical choice but it actually introduces some risk. If a molder is narrowly focused, an industry downturn or perhaps the loss of a major customer could topple their business &#; and you&#;re left without a supplier. On the other hand, diversified injection molders bring a balanced scope of expertise and stability that strengthens their partnerships across the board.
2. Appropriate certifications
Understandably there isn&#;t a one-size-fits-all-industries approach to custom injection molding. Strict guidelines within the majority of markets are the norm, and supplier certifications are required. Documenting that injection molders hold credentials such as IATF : for automotive quality management or meet ISO : for medical projects is essential. Molders with rare and sought-after certifications such as MedAccred Plastics accreditation offer additional expertise that benefits the specific industry and complements others.
3. Design depth
The design phase of any project is critical. It is also an opportunity to affordably optimize all facets of manufacturing, including cost and quality. The key here is partnering with an injection molding partner that is trained and well-versed in advanced analysis methodologies such as Design for Manufacturability (DfM).
4. Engineering support
Collaboration among OEM and molder engineering teams can lead to efficiencies and solutions that improve injection-molded parts. An injection molder should fully support product development and offer engineering support related to design, testing, manufacturing, and assembly.
5. Quality Control
Injection molding requires precision. To that end, custom injection molders should have regimented processes in place. It&#;s imperative you understand how quality control factors in &#; not only as a molder&#;s internal mechanism, but also as it translates to maintaining OEM quality standards. It could make or break the partnership.
6. In-house tooling
Tooling is a vital &#; and often expensive &#; part of the injection molding process. Tool quality and part quality are inextricably linked as tools dictate how well design specifications are met. Injection molders with in-house tooling capabilities keep rework to a minimum while maximizing quality and production efficiencies.
If you are looking for more details, kindly visit Wingtat.
Using this 6-point assessment to select potential injection molding partners will save you time and probably some frustration. It will also likely point you to Kaysun. Our broad-based custom injection molding experience and proven expertise across the medical, automotive, consumer, and industrial markets ensures we have the capabilities and desire to truly partner with you to achieve your part, production, and budgetary goals. Over 75% of our business is done with partner customers who have been with us 5 years or more (some much more). This is evidence that our partnership strategy works.
Learn more in our guide, How Injection Molder Partnerships Influence Project Costs. Click the button below to download your copy now.
Key 1: The nature of the injection product
There are certain ideas for plastic injection products, which can be simpler and clearer when choosing an injection molding machine. If you have any questions when purchasing an injection molding machine, you can directly ask the supplier of the machine according to the requirements of the product. You can provide ideas to discuss the actual product that is injected with the injection machine company. If there is no actual injection product, there will be more communication problems. For example, does the company have set the product to be produced with a plastic injection machine? Is it a general household item? Or are there special-purpose parts? Does the injection product have requirements for temperature, light transmission, softness, or weight? Should the product material use thermoplastic plastics (such as ABS, PE, PP, engineering plastics) or thermosetting plastics (FRP, LSR)? Is it necessary to make high-precision and high-density products to meet the needs of the product (such as automobiles, communications)? Should the product color be used for single-color injection or two-color injection? These are the questions that we often encounter from customers, so you must clearly understand your needs, and then determine the nature of the product is one of the very important homework.
Key 2: Mold size, product size
If we just want to shoot a small plastic doll, the size of the mold will naturally be smaller, but if we want to shoot a trash can today, the mold will be much larger. It can be known from this that if the product to be injected is larger, the mold will be larger, so the injection molding machine must be larger. In addition to understanding the size of the product to be developed, it is also necessary to know that the size of the mold that each injection machine can use is different. Therefore, instead of calculating the approximate size of the mold by yourself, it is better to consult a number of mold factories to understand the size of the mold, and then determine whether the inner distance, mold thickness, and size of the machine can be placed according to the mold size.
<Extended reading: What is the Corinthian Pillar? &#;
Key 3: Mold opening stroke
Generally speaking, a mold is divided into two parts: a male mold and a female mold. The product structure and appearance geometry we design is to design a film cavity in the male and female molds, and then inject the plastic materials into the film cavity. Here, after the plastic material is injected, the "mold opening" will be performed, which means that the male mold will be opened backwards, and then the finished product will fall out from the female mold, which is "demolding". The maximum distance that the male mold can be separated from the female mold is called "mold opening stroke". When purchasing an injection machine, in addition to the product size mentioned just now, how long the length of the mold opening stroke is, it is also a very important point, otherwise it may happen that the product cannot be taken out after injection into the mold.
Key point 4: Clamping force
After the injection machine injects the plastic into the mold, in order to keep the shape of the finished product, it will maintain a certain pressure on the product, and the plastic itself will also give a reaction force to the outside. Therefore, in order to prevent the mold from being completely opened and the phenomenon of supporting the mold, the clamping unit of the machine will give "clamping force". The clamping force can also be calculated according to the product area, size, material and other factors. However, if you want to know how much clamping force your product needs, it is recommended to consult a professional to avoid insufficient clamping force calculations. There may be burrs and glue overflow to the injected products.
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Is there any relationship between the flash of the product and the strength of the template? &#;
Key point 5: Injection volume
The injection volume will vary with the weight of the product, the material, the number of cavities of the mold, etc., but usually the larger the weight and volume of the product, the larger the tonnage of the machine, otherwise it may not be able to manufacture. This is related to the "screw" in the machine. The screw is horizontal in the machine. It pushes the melted plastic material to the injection port before injecting the plastic. It also melts, compresses, and mixes the plastic in the process. The longer the diameter and stroke of the screw, the larger the volume of the finished product that can be injected. So when choosing an injection machine, not only need to look at the tonnage of the injection machine, but also pay attention to the diameter of the screw by the way.
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Key point 6: Screw compression ratio
We just mentioned the screw in the injection machine, and explained what its work is. Let's explain the work of each section of the screw more clearly. The screw is divided into three sections. The order from feeding to injection is: feeding section, compression section, discharge section.
Feeding section
: the plastic pellets that have not been melted are transferred to the compression section, where some plastic pellets will be slowly melted.Compression section
: plastic is compressed and mixed.Discharge section
: the plastic will be completely melted, and the temperature and particle mixing should also be completely uniform.
The screw compression ratio stated in the title is about the groove depth of the feed section/the groove depth of the discharge section. There is no best number for screw compression ratio, because each type of plastic has different properties, so you should seek professional manufacturers to evaluate the compression ratio production to have the best production quality.
Point 7: Injection speed
When the injection machine is producing thin-shell products, the injection speed of the injection molding machine must reach a certain value before production can be produced to avoid the failure of production due to cooling when the filling is completed. In addition, it should be noted that the higher the injection speed, the mold exhaust and the higher the accuracy requirements, the overall planning is required.
Key 8: Other requirements for finished products
We often hear that customer products have relatively high standards for appearance, function, quality, etc. or other applications and requirements, such as gloss, surface brightness, fire rating, environmental protection rating, etc. Some factors are quite related with the plastic material, but some are also related to whether the injection machine itself can support this function, so if you have requirements for product quality, it is recommended to ask first to see if the injection machine can meet your needs. We are committed to helping customers solve problems and tailor-made professional companies for customized injection molding machines. If you have any questions, please feel free to ask.
Conclusion
The above 8 points are the key considerations when choosing an injection molding machine. Of course, there are many considerations and attentions in the injection molding process, such as mold making and plastic selection. The customers often encountered affected the finished product because of the wrong shape or material selection of the product itself. Later, after repeated communication to modify the mold in the injection machine, or to change the material to solve it. We are a professional injection machine expert who has been operating for many years in the local area. We care most about is the "quality" of the product. If you want to learn more about our expertise, please continue to pay attention to our blog. We are happy to share more about plastic knowledge of injection molding to everyone.
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Are you looking for a new injection molding machine for the company's new products, or want to upgrade the injection molding machine in your factory, but you don't understand a bunch of proper terms on the Internet? What is "mold opening stroke"? What is the "Tie-bar"? How to judge whether the "screw diameter" is suitable for your product? In this article, we have sorted out 8 key points and selection suggestions for you to teach you how to select the injection machine correctly, so that you can purchase accurately and save costs. The following are our key points:There are certain ideas for plastic injection products, which can be simpler and clearer when choosing an injection molding machine. If you have any questions when purchasing an injection molding machine, you can directly ask the supplier of the machine according to the requirements of the product. You can provide ideas to discuss the actual product that is injected with the injection machine company. If there is no actual injection product, there will be more communication problems. For example, does the company have set the product to be produced with a plastic injection machine? Is it a general household item? Or are there special-purpose parts? Does the injection product have requirements for temperature, light transmission, softness, or weight? Should the product material use thermoplastic plastics (such as ABS, PE, PP, engineering plastics) or thermosetting plastics (FRP, LSR)? Is it necessary to make high-precision and high-density products to meet the needs of the product (such as automobiles, communications)? Should the product color be used for single-color injection or two-color injection? These are the questions that we often encounter from customers, so you must clearly understand your needs, and then determine the nature of the product is one of the very important homework.If we just want to shoot a small plastic doll, the size of the mold will naturally be smaller, but if we want to shoot a trash can today, the mold will be much larger. It can be known from this that if the product to be injected is larger, the mold will be larger, so the injection molding machine must be larger. In addition to understanding the size of the product to be developed, it is also necessary to know that the size of the mold that each injection machine can use is different. Therefore, instead of calculating the approximate size of the mold by yourself, it is better to consult a number of mold factories to understand the size of the mold, and then determine whether the inner distance, mold thickness, and size of the machine can be placed according to the mold size.
What are injection molding machines? What are the types?
We just mentioned the screw in the injection machine, and explained what its work is. Let's explain the work of each section of the screw more clearly. The screw is divided into three sections. The order from feeding to injection is: feeding section, compression section, discharge section.The screw compression ratio stated in the title is about the groove depth of the feed section/the groove depth of the discharge section. There is no best number for screw compression ratio, because each type of plastic has different properties, so you should seek professional manufacturers to evaluate the compression ratio production to have the best production quality.When the injection machine is producing thin-shell products, the injection speed of the injection molding machine must reach a certain value before production can be produced to avoid the failure of production due to cooling when the filling is completed. In addition, it should be noted that the higher the injection speed, the mold exhaust and the higher the accuracy requirements, the overall planning is required.We often hear that customer products have relatively high standards for appearance, function, quality, etc. or other applications and requirements, such as gloss, surface brightness, fire rating, environmental protection rating, etc. Some factors are quite related with the plastic material, but some are also related to whether the injection machine itself can support this function, so if you have requirements for product quality, it is recommended to ask first to see if the injection machine can meet your needs. We are committed to helping customers solve problems and tailor-made professional companies for customized injection molding machines. If you have any questions, please feel free to ask.The above 8 points are the key considerations when choosing an injection molding machine. Of course, there are many considerations and attentions in the injection molding process, such as mold making and plastic selection. The customers often encountered affected the finished product because of the wrong shape or material selection of the product itself. Later, after repeated communication to modify the mold in the injection machine, or to change the material to solve it. We are a professional injection machine expert who has been operating for many years in the local area. We care most about is the "quality" of the product. If you want to learn more about our expertise, please continue to pay attention to our blog. We are happy to share more about plastic knowledge of injection molding to everyone.
For more information, please visit Rapid Tooling Injection Molding.