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July 16, 2013 When I first got started in mold making for plastic injection molding companies in Melbourne in 1989, I was surprised by the high capital investment required just to start a molding business. The cost to purchase new machines was high so injection molders always tried to get the lowest price possible but for some reason the cost of long set up times, making reject parts and energy consumption were not much of an issue. Today, however, it is a different story. Plastic injection molding companies are under constant pressure to make better quality parts at lower prices with shorter delivery lead times. So as a molder, why would you settle for a cycle time of 30 seconds when it is possible to have 24 seconds. What’s more, why would you invest hundreds of thousands of dollars in machinery and moulds that will not live up to expectation? In short, if you are involved with plastic injection molding as a process technician, business owner, engineering manager or mold maker then we would like to save you five years of learning so that you can:
Produce better quality parts Reduce cycle times Reduce set up times Reduce your energy bill Save plastic material
After all, in order to deal with the pressure of today’s overseas competition and increasing energy costs it is essential that you have a well managed business that uses as few resources as possible while still adding value to your customers. In other words, having a lean manufacturing business. So if you desire flawless production (as in the video below) here you can read about the best ideas and techniques for increasing productivity that we have learned and developed over the past 20+ years.
Lean Manufacturing Principles And Their Benefits
Lean manufacturing principles were used to create lean techniques that aim to build and maintain the most efficient manufacturing business possible. One of the key principles in lean manufacturing is to view things from the customers perspective. Getting and using feedback from customers about your product line will ensure you make products that satisfies their needs.
What’s more, customer feedback ensures resources are not wasted on making a product that has features that they are not interested in and not willing to pay for.
How Can Lean Manufacturing Principles Benefit Injection Molding?
Many people initially believe that lean techniques are mostly about cost reductions. In fact, they provide the one feasible way to cut costs while also shortening lead times and times to market, improving quality, and providing customers with exactly what they want precisely when they want it. One of the principles used to achieve these benefits is to eliminate all waste in a manufacturing process. Waste is any action that does not add value to the end customer.Click here to learn about the 4 most common mistakes in injection molding. In injection molding, the most obvious example of waste is making defect parts. A less obvious example is energy consumption used to make each part. Just because you use 30% more energy than your competitor, it doesn't mean customers are willing to pay more for your parts. They will go for the cheapest price. This is why molders need to identify areas of waste. There are literally dozens of examples of waste in plastic injection molding plants such as longer than necessary cycle times due to poor part design, poor mold design or operator incompetence. Click here to learn how to reduce cycle time and save costs. Another example is the lack of training in proper molding techniques. Insufficient training can result in costly mold and machine damage. When properly implemented, lean manufacturing principles can deliver many benefits. Some other benefits include:
Higher employee morale (which naturally improves productivity) Establishing a reputation as a quality and reliable supplier (this will increase your customer base)
Given these benefits, one would think lean implementation would be standard practise in the industry but this is not the case. During the past 20 years western plastic injection moulding companies preferred to move some or all of their manufacturing operations offshore to low cost countries such as China, India, Malaysia, Vietnam and the Philippines. Fortunately, this trend is showing signs of reversing mainly due to the realization that profit margins were not as high as expected because of ongoing quality issues and other unexpected costs. As a result, injection molding and mold making industries are slowly recovering in many western countries such as Australia and America.
As this trend continues, it will not be sufficient to just sit back and wait for a full recovery. Long term survival of an injection molding company hinges on the ability to eliminate waste across the entire firm and make parts that satisfy customers needs. Lean manufacturing principles provide a vehicle to see where waste exists and how to eliminate it. One would expect that these principles will grow in popularity now that off shoring has not lived up to expectations.
One of the most common techniques is lean 5s. Click here to learn how lean 5s can benefit your injection molding business. Another common technique is the 7 wastes. Click here to learn how the 7 wastes can benefit your injection molding business.
Convincing Upper Management
The biggest challenge is getting long term commitment from upper management. They need to understand how the long term benefits of implementing a lean manufacturing program outweigh the short term inconvenience of modifying the way employees think and participate in a firm. Guaranteeing Worker Job Security Workers naturally feel threatened by any change in their job roles – especially one that involves cost cutting. That’s why it is critical that upper management guarantee job security at the beginning of a lean program and keep this promise. Over time employees will gain confidence in the changes as they see the benefits of a program. The result will be constructive participation by all employees.
To be most effective using lean manufacturing principles the concept needs to be embraced across the entire company. A lean manufacturing program should cover all aspects of the business. It can be applied to office environments as well as manufacturing processes. Just cherry picking certain areas for improvement will not give long term sustainable benefits to the company.
4 Injection Molding Mistakes To Avoid
Avoid the most common injection molding mistakes if you are starting a plastic injection molding manufacturing business and begin on the correct path. Understand that injection molding is not as easy as it looks and there are so many hidden costs that are not visible until you are already in too deep.
1. Poor Project Management
At the start of any new molding project, there are a number of people that need to come together to discuss the best way to design and make a new part. Part designer, mould designer, mold maker, moulding technician, plastic supplier, machine supplier , relevant management staff and the end user need to discuss and find solutions to any possible impediments to an efficient manufacturing process and product application. Such things as part design must be analysed by all people so that potential manufacturing and application issues are eliminated before making a mould. Projects that start on the wrong foot almost never fully recover from mistakes because it is simply too costly and time consuming to do so. The result is a high manufacturing cost, a sub-standard product and tension between people.
2. You Get What You Pay For
Buying a cheap mould (especially from a low cost country) is a guaranteed way of having ongoing quality and productivity issues. Common issues with cheap injection moulds are the use of sub-standard steel, poor mold design and poor mold building. The worst part about these issues is that they cannot be fixed unless a new mold is made. What’s more, a poor quality mould will damage a moulding machine so maintenance costs will be high. Similarly, buying cheap machines will also give ongoing part quality and productivity issues. If buying a used molding machine then make sure it has been fully reconditioned and tested before delivery so no time is wasted troubleshooting upon mould commissioning. Click here to learn how to buy used machines that work.
3. Lack of Training
The plastic injection molding process is complicated and often management do not appreciate this fact. Consequently, process technicians do not get the training they need to be able to set up molds and make parts efficiently and consistly.
The time and cost spent troubleshooting issues could have been put toward proper training techniques in the beginning so that problems could have been avoided in the first place. No Lean Manufacturing Program This is the biggest injection molding mistake by far. Lean Manufacturing Example . A lean manufacturing program would not only solve the 3 previously mention mistakes but also would address other inefficiencies in an injection molding company. Instead management are considering investing hundreds of thousands of dollars in new machinery with new technology. Have you ever noticed in a manufacturing company how a certain culture exists whereby a particular level of production becomes acceptable and few people are willing to question how much more productivity is possible with the existing machinery? The machine operator might have become complacent because the management have also become complacent or the management don’t have the technical background to understand how the process could be improved. Before investing in new equipment why not see how much more productivity your existing machinery has to offer? Cycle Time Reduction If cycle time is reduced by 5% then productivity will increase by 5%. . The technique I use in this example is based upon my 5% Rule. 4. The decision to implement a lean program must come from top management so that every single person in the company cooperates and contributes to a better bottom line and happier working environment.How To Make Your Injection Molding Business 5% More Productive Immediately And Save Costs Here is a lean manufacturing example that will get injection molders at least 5% more productivity immediately without spending a dollar. My 5% Rule says that most injection moulding machines can give at least 5% more productivity because cycle times have not been optimized. All waste would be eliminated over time.
If the cycle time is reduced by 5% then the cycle becomes 8.3 2.1 seconds. Mould closing 2.000 per year.0 Total 9.5 6.5 seconds. if there are ten machines in your company with the same production requirements the extra sales revenue will be $400.2 3.6 seconds which means some part of the cycle needs to be reduced by 0.000 in sales revenue per year per machine . In the injection moulding process there are typically 6 phases that occur during each cycle. Ejection 1. And how do I expect to achieve this 5 % extra productivity immediately without any investment of money? Let me explain with a lean manufacturing example. If the annual requirement of this part is 400.Take.a tidy return for very little investment of time. Injection of plastic into the mould 3.000 parts which is 20. What’s more. Holding of plastic in the mould to allow proper formation of the container 4.000 then with 5% more productivity this machine will produce 420.1 5. Lean Manufacturing Example Consider the same injection moulding machine producing a food containers with a cycle time of 9. Injection 1. The 6 phases: 1.000 more parts per year.5 seconds. And if each product sells for $2 then this is an increase of $40.0 4. Australia running a 2 cavity mould. the first thing considered was the phase that would have the smallest effect on part quality. Opening stroke of the mould 6. .1 In order to reduce the cycle time by 0. This was the ejection time. Ejection time. Closing 1. Hold 2. The 9.1 second cycle time had the following breakdown: Phase (seconds) 1. Opening 1. the container can be physically ejected off the mould The following is a real life example performed on an injection molding machine in Melbourne. Cooling of the container so that it is rigid enough to eject from the mould 5. Cooling 2. an injection molding machine producing a food container part. for example.
Hold 2. therefore. on some molding machines the plasticizing screw recovery time will have an effect on cycle time if the machine doesn't have a shut off nozzle. Although the part shrinkage was slightly more it was still within the quality limits and made no difference to the end user. Additionally. Injection 1. In some cases the mould and machine might already be operating at their limits so it is not possible to reduce cycle time.8.0 unchanged 4. Here is a summary of the changes: 1. For example.2 2.1 reduced to 2. Cooling 2. Injection moulding companies have millions of dollars invested in machinery and tooling so it is vital to get the most out of them. There was no need to wait for the moving side to completely stop before starting the ejection stroke. This means there are several combinations that could be used to reduce the cycle time. leading hand or moulding technician you should be asking yourself how can I improve productivity by 5% today? Exercise I would like you to choose one moulding machine in your company that is producing a part with a stable cycle time and attempt to reduce that cycle time by 5% by using the above lean manufacturing example as a guide. .8 Total cycle changed from 9. Another 0.2 unchanged 3.6 seconds without effecting quality Additional Comments From this case study one can see that there are 6 parameters that could be used to share the 0. Also.2 seconds earlier while the mould was still in the opening stroke. To see what works best. the ejection time was reduced to 0. the opening and closing times were reduced by 0.4 6. Ejection 1.In this example the ejection was started 0. The right mindset is important to run efficiently as possible so as a factory owner.5 seconds.5 second reduction in cycle time.3 reduced to 1. in the above example as it turns out the hold time could have been reduced by 0.2 seconds by reducing the opening stroke.1 to 8.0 5.1 was subtracted from the cooling time which achieved our target of 0. manager. It’s a matter of looking at each mould and machine combination on a case by case basis.1 each saving another 0.0 reduced to 0.5 reduced to 1. Closing 1. Opening 1.2 seconds without any change in part quality.
board or cabinet so that they are easy to find.Sorting Sorting involves collecting the tools you need and discarding the tools you don’t need. In injection molding some of the tools a die setter needs daily are allen keys. reduced operating costs. Broken or lost tools are replaced or fixed so that tasks are completed quickly. The tools needed should be sorted into 3 categories. Target one machine per week and just see how much more productivity can be achieved. the second are the tools that are used only occasionally and the third are the tools that are used once or twice a year. 5s eliminates time wasting because tools are easy to locate and are in good working order. They are usually secured to a wall which is easy to see from a distance and are located in a convenient position such as next to a molding machine. a torque wrench and eyebolts. You might be surprised how much difference it could make. Tools required occasionally are used for machine maintenance such as tapping a hole in a platen and tools required once or twice a year are for machine servicing or repair.Straightening out or simplifying This means organizing the workspace so that all tools belong to a dedicated trolley. use and return. Use this approach on every machine in the company. What Is Lean 5s About? It is about people organising their workspace into a safe and structured layout so that tools such as allen keys and eye bolts are easy to find and use. Steps In 5s Lean There are 5 steps: 1. .And once you have established a 5% cycle time reduction on a particular machine. Lean 5s – The First Step To Improving Productivity A plastic injection molding company practising the lean 5s method will benefit by having faster set up times. try reducing the cycle time by another 5% until quality issues become your limiting factor. The first are the tools that are used daily. a visually attractive workspace and higher employee morale. 2. shadow boards are common (right). For tools used on a daily basis.
3. dust or anything else that is not supposed to be present(right).Shining or Sweeping This means cleaning everything in the workspace so that it is free of residual oil. . This helps to promote a safer and more enjoyable work environment. dirt .
5s will only work if management are committed to it. safe. One way of doing this is for one manager to manage by walking around and report on the tasks that have not been done and holding people responsible. For example.Standardizing Standardizing is about implementing practices that are consistent throughout the work place.4.Sustaining This is about doing the previous 4 steps in the long term. The 7 areas analyzed are: Defects Over Production Over Processing Waiting . neat and tidy makes everyone feel better and what is even better is that this can be used as a motivational tool for the company to implement the next lean manufacturing method. at the end of shift all shadow boards should be checked and any missing tools found so that the next shift doesn’t have to waste time searching. What Are The 7 Wastes About? It is a lean method which identifies key areas of waste in a manufacturing process. Having a workplace that is clean. It is about identifying which steps add value and which steps do not. higher profits and will produce better quality parts. 5. The Benefits Of The 7 Wastes A plastic injection molding company using the 7 wastes method will benefit by having reduced costs. Additional Comments The biggest benefit of implementing a 5s program is that the results can be seen immediately. All workspaces must have common rules that are easy to use so that everything is kept well organized.
. If your reject rate is 10% then your production time is 10% longer and you use 10% more material – your customer will not reimburse you for this. potentially blowing out delivery lead times and having to deal with angry customers. If an assembled part is made up of 2 pieces and one part has a shorter cycle time than the other then this is over production. Transportation Motion Inventory 1. 4. The customer will not pay more if the parts are in the upper range even though it cost more to make.Defects It takes just as much time and energy to produce a defect part as it does to produce a good part. equipment or people is a sign of poor planning if it happens on a regular basis. other jobs which were scheduled to go into that molding machine have to be delayed.Waiting Waiting for materials.7 grams to save material cost (assuming nothing else is effected). Making a defect part is costly because not only does the part need to be made again which uses more material and time. Why not modify the part and mold design so that both parts cycle at the faster cycle? 3. If the specified part weight is 15.Over Processing Over processing is seen as any extra unnecessary step that does not add value to the process. 2. There is waste in this process in two ways. The first is in having to hold extra inventory of the slower cycling part so that the assembly station does not have to wait. An injection molder is expected to produce parts that fall within certain quality specifications for his customer to accept them.Over Production Over production means producing parts before they are required.0 grams plus or minus 0. The second is the extra time it takes to make the part with the longer cycle time.3 grams then it’s better to aim for the lower range of 14.
huge benefits will naturally flow to both the injection molder and their customers. Having an excess of plastic material not only ties up money. Every time something is transported.Transportation Moving raw plastic material to a molding machine and then moving the molded part to the storage area is transportation.the most efficient path is not always taken. To minimizing transport study your factory layout. 7.Motion Unnecessary movements are a waste of motion. 6. 5. it is also at risk of being damaged or lost and having to be made again. Having more inventory than required ties up money that could be used for other things. Although transportation is necessary. Plastic Injection Molding Machine Selection – Why It Is Important If you select the right plastic injection molding machine you will make quality parts consistently and profitably. it consumes valuable floor space. This is a result of poor factory layout.It will also help you keep your costs low which will make you . Additional Comments The 7 wastes is a powerful method in identifying and eliminating waste in the entire manufacturing process. When this mind set is reinforced over time.Inventory Inventory relates to raw materials and finished goods. Waiting adds to the manufacturing cost of each part made because it is effectively increasing cycle times. The seven wastes is also about encouraging people to think differently about their work environment. If tools are not in their proper place and a die setter needs to go searching for them then this is wasted motion. not only does it take time and energy. But it is more than this.
Even better. It is advisable to have at least 10% injection pressure in reserve so . Mistake #3 Injection Pressure Limited. Mistake #1 Buying Used Injection Molding Machines That Don't Work The key to buying a reliable used machine is to find one that has been fully inspected and tested before delivery so that you won’t suffer loss of production due to multiple breakdowns. To consistently make quality parts the molding process must not be limited by the injection pressure. Mistake #2 Selecting Large Screw Diameters. this can also degrade the material and is likely to lead to reject parts. Large screw diameters can cause quality problems due to material degradation. How To Keep Your Costs Low: Minimize reject rate (set a target <1%) Reduce energy consumption of all injection molding machines Have faster cycle times Eliminate unscheduled machine downtime –(no breakdowns) A properly selected plastic injection molding machine will give you all of the above. Common Machine Selection Mistakes And Their Consequences Perhaps the best way to appreciate the importance of correct plastic injection molding machine selection is to list the most common mistakes made when selecting machines and the effect on part quality and productivity. the plastic material spends more time being heated by the barrel heaters compared to large shot sizes. Click here to find out how to buy used injection molding machines that work. Another problem with large screw diameters are the large shearing forces generated during screw rotation.more competitive. Material degradation is likely to occur if the shot size is less than 15% of the injections units maximum shot size. earn more money and at the same time establish a reputation as a quality manufacturer. When small shot sizes are used with large screw diameters. You will be able to sell more parts. you will have the security of long term customers.
Mistake #4 Inadequate Clamp Tonnage If clamp tonnage is too low then it will be difficult to produce quality parts. flash. There are 3 types of machine designs: fully hydraulic.Click here to learn about how to reduce your energy bill on your existing machinery by changing parameters in the plastic injection molding process. Calculate the injection unit size. Know the plastic parts you intend to mold 2.Know The Plastic Parts You Intend To Mold The process of selecting the right machine starts with knowing the particular plastic parts that will be moulded by the machine. 1. Machine and mold wear will be excessive. The type of machine design also plays a significant role in power consumption. hybrid or electric 3. slow cycle times and machine and mold damage. A small mold will require almost as much energy to open and close the platen compared with a medium size mold. Mistake #5 High Energy Consumption Have you ever noticed how there is almost no difference in your cars fuel consumption with 2 people in it compared to just 1 person? A moulding machine is the same. You should know the part: Plastic material Weight .that the injection molding machine can automatically adjust to normal variation in the plastic material viscosity. Insufficient injection pressure will produce short moldings. short shots. Low clamp tonnage means inconsistent weights. Molding parts that are not suited to the machine will result in frustration with on-going quality problems. Select machine type: Hydraulic. Selection largely depends upon the type and quantity of parts to be molded. The injection units screw diameter governs the available maximum injection pressure so it is critical to choose the correct diameter when buying a plastic injection molding machine. Calculate clamp tonnage requirements 4. Hybrid machines are partly electric and partly hydraulically operated. fully electric and hybrid machines. A properly selected plastic injection molding machine will use power very efficiently. wall section variation. poor surface finish and size variation. Machine Selection Process 1.
8mm – this is known as thin wall molding.combination of hydraulic and electric drive Fully Hydraulic Machines The types of hydraulic machines available are defined by the type of clamp design. 2. Accumulators are required for molding of parts which have wall thicknesses in the range of 0. Clamp design is either a toggle clamp or by hydraulic ram. type of hydraulic pump design and the presence or absence of an accumulator. a variable displacement pump (also called a piston pump) or a servo pump (also called frequency control or RPM control) . Hydraulic pump design can be a constant displacement pump (also called fixed displacement pump).3mm to 0. while others use it for the injection stage only. Which one is suitable for you? It depends on your priorities.The correct part information will then allow you to find the injection unit size.Select Machine Type Types of plastic injection molding machine designs available: Fully Hydraulic Fully Electric Hybrid . clamp tonnage requirements and machine type. Length x width x height Average wall section Gate location Maximum flow length from the gate Estimated cycle time Quality requirements Annual quantity requirements In addition you should also know the mould size and weight. Here are some criteria to consider before selecting a hydraulic moulding machine: Buy a new or used machine Purchase price Energy efficiency Plastic material to be processed Part design Mould design Clean room requirement . Accumulators might also be required for moulding thicker parts but this must be checked on a case by case basis. If an accumulator is present then some machine manufacturers use it to drive the entire machine.
Hybrid Plastic Injection Molding Machines A hybrid plastic injection molding machine uses a combination of hydraulic drive and electric direct drive. However. The hydraulic drive is used to generate fast injection speeds when moulding thin wall parts. In order to find the tonnage using the simple calculation the following part information is required: Plastic material Length x width x height Projected area (length X width) . the purchase price is 10%-15% higher than a hydraulic machine with a constant displacement pump or even a variable displacement pump. (Click here to find the machine clamp tonnage for plastic parts made from polypropylene). A servo pump will only operate when the machine requires movement. Click here to learn more about electric molding machines. the rest of the time it is using minimal power. Click here to learn more about medical injection molding. These injection molding machines are very energy efficient 3. the mould opening/closing stroke has its own motor. This makes them suitable for molding medical devices. Fully Electric Plastic Injection Molding Machines Every movement of the machine is done with direct drive electric servo motors only drawing power when movement is required so they are very energy efficient.Calculate Clamp Tonnage Requirements Clamp tonnage requirements for your plastic injection molding machine can be calculated by: By experience – injection molders and machine manufactures have this information Computer simulation – using software such as Mold Flow By a simple calculation Projected Area X Average Cavity Pressure X Number of Cavities. For example. The rest of the machine uses electric drive servo motors and each axis of the machine has its own dedicated motor. Electric machines are suited to clean room operations because there is no hydraulic oil that can leak on to the floor. Cycle time requirement Hold time requirement Local service agent capability If low power consumption is a priority then choose a hydraulic machine with a servo pump as this is the most energy efficient of the fully hydraulic machines. Electric machines have excellent repeatability which virtually guarantees consistent part quality. Keep in mind a servo pump control will only save you power if you have long cooling times or machine inactive times such as long take out time for robot.
4.Calculate The Injection Unit Size To select the right unit for your plastic injection molding machine you must know part: Plastic material Cycle time Cooling time Shot weight (part weight. Parts with long flow paths and thin walls will have pressures in the upper range while parts with short flow lengths and thicker wall sections will have much lower pressures. you need to know the mold weight and size so that you can check that the mold will physically fit into the machine and that the machine can carry the mould weight.91 grams per cubic centremeter Calculation to find barrel capacity for PP is: . What is the barrel capacity for polypropylene (PP)? Density of GPPS = 1. Average wall section Gate position Maximum flow length from the gate Number of cavities in the mold The average cavity pressure is also required and this information is available in some plastic injection molding machine manufacturers hand book for certain materials. Most barrels are rated in grams of general purpose polystyrene (GPPS). Both units usually have 3 different screw diameters on offer.06 grams per cubic centremeter Density of Polypropylene = 0. Most injection molded parts average cavity pressures lie in the range of 300-800 bar. Lets assume we have a barrel with a screw diameter of 56mm and the capacity is 510 grams of GPPS. Plastic material selection also influences the cavity pressure. In addition. cold runner weight and number of cavities) Peak injection pressure requirement Plasticizing rate Injection rate Hold time and pressure For a specific tonnage machine. In order to select the correct diameter the shot size must be calculated as a percentage of the barrel capacities and must lie between 15% and 80% so that good quality parts can be made. manufacturers usually offer 2 injection units to choose from. To calculate the shot capacity for materials other than for GPPS the density needs to be known (which is available in most molding books or can be found online by doing a search).
06)x510 grams=438 grams PP So maximum barrel capacity for this 56mm screw diameter is 438 grams. If you are like many injection moulding companies you may be searching for the perfect blend of price. Click here to learn more about screw selection. Just remember. quality.(Density of PP/Density of GPPS)xBarrel capacity of GPPS grams =(0. delivery time. "How To Buy Used Injection Molding Machines That Work" "Let Improve-Your-Injection-Molding. Next we need to make sure the shot size is within the maximum and minimum limits of between 15% and 80%. Be sure to check the screw diameter is the same.perhaps you have a similar part in production in which case you can read the pressure directly off the screen.it is the easy way to grow your company on a budget" Hello. . the following 3 criteria must be confirmed to be within limits of the injection unit with the 56mm diameter screw. the screw diameter selected is crucial to long term part quality and productivity. Next.91/1.com get the right used injection molding machines for you . Injection pressure Plasticizing rate Injection rate These can be found in one of 2 ways: The first is by experience . The second is by computer simulation but keep in mind the results are only as good as the information that is entered. If the shot size for the injection mould is 110 grams then the shot size as a proportion of the total barrel capacity is: =(110/438)x100= 25% which is within limits. reliability and backup service. It is advisable to check these results against some real life examples.
If you are becoming frustrated in your search for the ideal used injection molding machines for sale then we might have the answer for you. Fast Delivery And Commissioning Service . New servo pump and control can be retrofitted to specifically designed machines normally of German origin. Fully tested machines will give you 5 to 7 years production .so you know you are buying machines that will work and be safe to use. Click here to skip down to the Quoting Contact Form We Source The Right Machines For Your Needs We find the right machines for the particular plastic parts you intend to mold. materials being processed and age of the machine. And we ship to any country. This will ensure they will be able to produce your plastic parts to the specified quality. Energy Savings Significant energy savings are possible with some models of machines – saving you lots of money. We do the work so you get the best used injection molding machines. You won't have to suffer the time and frustration of troubleshooting and employees will be free to perform their daily tasks without interruption. When searching for used machinery we will target younger machines so that we can ensure that the continuity of supply for the electronic equipment and control can still be sourced. This means you will produce high quality parts consistently and profitably. All machines are run and engineering parts are checked for the need to be replaced or refurbished. the machines will start satisfying customers’ orders and earning you money immediately. Get Fully Tested Molding Machines All moulding machines are fully tested before delivery . And this will win you the respect of your customers so you'll get repeat orders and feel a terrific sense of satisfaction. Best of all.giving you time to save for the capital investment required to buy into new technology machines. It’s impo rtant to keep in mind that machine life depends upon cycle time.
Most other machine suppliers will not give any guarantee at all – if you are lucky you will get 30 days. We must be confident you will be satisfied.this is all part of the purchase price. All used injection molding machines will be inspected and tested by us. This gives you the security to know you will get your machines. Just purchasing a machine that has been reconditioned by some international warehouse seller does not guarantee that the machine has been repaired correctly and that all functions are operating properly. It is critical that these additional repairs are carried out to ensure that our 12 month guarantee on repair labour can be given. At the completion of inspections and tests the machines will normally require additional repairs and parts to be installed that will bring them up to the standard that we will support. If it wasn't we would be foolish to offer such a long guarantee. you have the added security that it will function nearly as well as a new machine. So it must be everything we say it is. And the sooner you complete each order. Only the best used injection molding machines we will offer to our customers and stand behind them for the duration of their production. It is normal for us to reject at least 50% of the machines we inspect. Fair Final Payment Terms Final payment not required until you see the completed shipping documents. a commissioning service is all part of the cost. Some machine suppliers require final payment 5 days BEFORE shipping.Machines are normally ready for shipping in about 4 weeks but can be as little as 2 weeks if already completed and in stock. This is why we must inspect each machine that we supply to our customers. On top of that. With such a short delivery lead time. you can start taking orders from your customers straight away. 12 MONTH GUARANTEE 12 month Guarantee on labour (Warranty). Only a really honest and established company would give a guarantee like that on a used machine. . It doesn't matter which country you are located it. the sooner you will get paid avoiding cash flow problems. Once machines have been shipped to your country an experienced engineer will be be on his way to commission the machine.
We make sure you won't have to struggle. hydraulic drawings and operational manuals otherwise we will not support the purchase of it.Training Free Of Charge On-site training after machine installation is free of charge. For one full day your molding technicians will learn how to use the machine more efficiently so you will be more productive and you will earn more money and your machine and moulds will last longer. Free Help By Email And Phone If you get stuck you can get help and advice so you will never be left on your own. All Machine Manuals Supplied The manuals will ensure you get long term productivity out of the machine because it holds information about: Correct oil grades When to replace filters Maximum mold weight Minimum mold size All used injection molding machines must have full electrical drawings. your molding technicians can apply this knowledge to every machine in your company so productivity will get even better. Mold And Machine Package Option If you require new molds for your machines we can offer these as a package. There are a number of advantages to this: It is cheaper than buying them separately Eliminates interfacing problems Will produce quality parts consistently and profitably Will be easy to setup and maintain Both mold and machine are guaranteed Now’s The Time To Get A Quote . What's more.
service and back up provided to my company over the ten years that it has been operating. I had to upgrade my machines.If you know what machines you need we can probably quote based upon your specifications. Take a peek at what one of our customers had to say : Approximately five years ago I was faced with the problem that the moulding machines I had were too old. In the first half of 2010 I purchased an L/T Demag Ergotech 200. I decided the most affordable option was to buy refurbished used injection molding machines out of Singapore. Keep in mind that not all machine manufacturers can supply the technical information and backup needed to keep the machines operational and the customer supported at all times. Since then I have purchased another 5 KM series Kawaguchi machines out of Singapore ranging in size from 50 to 280 tonne. which had been refurbished in my factory. however. backup information. . For my company to remain viable. into more complex multi-cavity tooling and enabled us to use a greater range of materials. a KM 360 B Kawaguchi. producing good quality. tested and every function operated for its performance capability – piece of mind to know that you will get long term repeatability. Overall I have been very pleased with the technical advice. I had been using Improve-Your-Injection-Molding for breakdown. I was impressed with the condition and performance of this machine. All these machines have proven to be very reliable and user friendly. We have a reasonable selection of well known brands that we will support and sell but not all brands will be offered to our customers. arrived in August 2007. you want to know what the best used injection molding machines are for the plastic parts you intend to mould then we draw upon 10 years of experience in helping our customers get the right machines. that is what I did. The machine is completely checked over. After careful consideration of the options. Continuity of spare parts. These machines have allowed us to broaden the type of work we can do successfully. This is also proving to be a very good machine. technical information and troubleshooting are most important to us and our customers. repair and servicing on existing machinery. run. This means we do the hard ground work for you so that you can start producing the best quality parts consistently and profitable in the shortest delivery time. It achieved a 40% power saving over my existing machines running the same product at the same rate. and as they were offering the service of going to Singapore to check the machines as they were being refurbished to ensure their quality was as anticipated. All of this at a reasonable price. including engineering plastics. When you order used injection molding machines from us you can rest assured that all priority equipment is measured and replaced if necessary. If. inefficient and unreliable. The first machine I purchased. consistent product.
nz What's more. Process parameters can heavily influence the energy consumption of a molding machine. . And click here to find out how to save costs by eliminating short shot quality issues. An important part of the plastic injection molding process are the process parameter settings such as hold time and screw plasticizing time. Process parameters give direct control over part quality and cycle time. Plastic Injection Molding Process Energy Saving Techniques The plastic injection molding process can start saving you money immediately. But they also have another function.Alan Myers Managing Director MT Containers Limited mtcontainersltd@clear. A recent case study we performed on a 260 ton Sumitomo hydraulic injection moulding machine showed that the electrical energy cost per part was reduced by 23% just by changing molding process parameters. By experimenting with process parameter settings you can potentially cut thousands of dollars a year off your energy bill. This gives you the confidence to know that we stand behind every machine that we sell because we know the quality of the machines in your company is crucial to your on-going success. Click here to find out about another way of reducing costs by fixing flash quality problems.net. How exactly do you find out the price of used injection molding machines and molds ? Fill out the Contact Form below including as much information as possible about the machines and molds you are interested in. I am about to show you how to use the molding process more efficiently. Click here to read about how plastic drying also influences part quality.com you can be sure you are starting a business partner relationship not just contacting a machine supplier. when you contact Improve-Your-Injection-Molding.
39 cents. Once barrel heaters and hydraulic oil were up to temperature production commenced and continued for one hour before the first energy consumption readings started. The electricity cost per part was calculated to be 2. In the first test. ongoing return. We want to help you get the same result by showing you how easy it is to do. See table 1 below for a list of all parameters. .0 seconds. For the 2nd test we chose to double the RPM speed of the plasticizing screw. A small investment in time for such a large. Cycle time remained at 18. A photo of the part produced is in figure 2. Case Study Equipment used: 260T Hydraulic injection molding machine with single cavity mold Chiller unit An energy meter (see figure 1) Also called a watt meter Procedure Disconnected moulding machine from mains power via circuit breaker and then connected the energy meter to the machines power supply.Cycle time was 18. the amount of energy consumed during a 30 minute period was measured with the original plastic injection molding process parameter settings.This result was achieved during a 6 hour production run.5% (without effecting quality) so the cost per part reduced to 2.31 cents.0 seconds. At the end of the 30 minute period we could see that this reduced energy consumption by 3.
8 0.2 2 stages 504 420 2 stages 0.8 0. RESULTS TEST NO.0 2.2 2 stages 504 420 2 stages 0.65 2 stages 0.7 to 5. 1 2 3 SAME AS 2 & REDUCED MOULD OPENING & CLOSING TIMES 4 5 PROCESS CHANGE INITIAL SETUP INCREASED SCREW RPM SAME AS 3 & CUT COOLING TIME SAME AS 4 & INCREASED INJECTION TIME CYCLE TIME seconds INJECTION TIME seconds HOLD TIME seconds HOLD PRESSURE bar COOLING TIME seconds PLASTICIZING SPEED rpm PLASTICIZING TIME seconds BACK PRESSURE 18.85 cents. Test 5 involved increasing the fill time from 1. All these results are in Table 1 below. Although the energy consumption slightly increased during the 30 minute time interval.7 seconds and the cost per part reduced again to 1.93 cents. the production quantity actually increased from 100 parts to 120 parts so the cost per part went down to 2. Test 4 was to cut cooling time by 3 seconds from 8.8 0.0 seconds.7 5.25 125 250 250 250 250 5.2 1. The result was an increase in cost per part to 1.7 5.55 2.55 2.2 1.06 cents.2 2 stages 504 420 2 stages 0.8 0.0 15.0 18.2 1.2 2 stages 504 420 2 stages 0.2 1.7 8.0 1.0 12.7 8.0 12.8 0.2 second to 1.2 2 stages 504 420 8. A 23% reduction in cost compared to test 1.55 2.55 4 stages 4 stages 224 4 stages 224 4 stages 4 stages 224 .In test 3 cycle time was reduced by increasing the mould opening and closing speeds.65 seconds and reducing the cooling time so that the cycle time remained the same as test 4 at 12.
3 1.0 1.0 1.0 300.6 25.18 PARTS MADE PER HOUR MATERIAL 200.18 0.75 15.0 15.9 32.3 1.2 0.1 70 70 70 70 70 1.0 300.7 27.1 1.0 1.1 1.5 1.8 22.2 18.18 0.5 30.1 450 450 250 250 250 1.1 26.8 .0 1.1 1.1 1.85 13.5 1.2 15.0 240.0 BARREL TEMPERATURES ⁰C MOLD HOT TIP ⁰C 235-230210-205 235-230-210205 235-230-210205 235-230210-205 235-230-210205 230 230 230 230 230 ENERGY CONSUMPTION PER 30 MINS kwhr ENERGY CONSUMPTION PER 1 HOUR kwhr TARIFF $ PER kwhr 13.18 0.0 200.18 0.bar 224 224 224 56 Set to maximum 224 224 56 224 224 56 224 224 224 56 Set to maximum 224 224 56 INJECTION PRESSURE bar Set to maximum Set to maximum Set to maximum MOLD OPEN TIME seconds MOLD OPEN STROKE mm MOLD CLOSE TIME seconds EJECTION STROKE mm EJECTION TIME seconds 1.45 16.2 22.3 12.
69 1.CONSUMPTION PER HOUR kg/hr ENERGY CONSUMPTION PER Kg kwhr/Kg 1.02063 0.332 0.000 then that translates into a saving of $2. And this was done just by changing some of the parameters in the plastic injection molding process.95 5.540 0.79 4.02313 0.02394 0.36 1.0 0. .63 4.93 COST REDUCTION PER PART cents 0.06 1.31 2. This translates directly into a 23% saving in electricity costs per part.80 COST PER PART $/part 0.01932 COST PER PART cents/part 2.51 1.081 0.85 1.41 COST PER HOUR $/hr 4.56 5.300 per year.462 % COST REDUCTION PER PART ZERO 3% 14% 23% 19% Results The results for this experiment show that for this particular machine producing this part.01854 0.39 2. Imagine if all of your machines could have at least a 10% reduction in cost then this would mean tens of thousands of dollars in savings per year. energy consumption was reduced by up to 23% from the original settings.75 1. If your annual electricity cost for this machine and part was $10. That's capital that can be used to grow your business.
The first group will only hold water on its surface (such as polypropylene) while the second group will absorb it into its internal structure (such as PET polyester). it easy for an injection molder to reduce electricity costs on existing hydraulic machines just by adjusting parameters in the plastic injection molding process.0. It is cheaper to make parts at faster cycle times with hydraulic machines. In test 4 the kwhr per kg reduced to 1. 7. 4. 3. SAN PVC ABS PPO ACRYLIC ACETAL PPS . 6. So there is a double benefit of having the fastest cycle time possible: the most obvious is the increased production output but the hidden benefit is the reduced electricity cost. Plastics That Need To Be Dried Before Processing: 1. The ability to reduce costs without having to invest in expensive new technology machines is totally in your control. In test 1 the kwhr per kg of polypropylene was 1. 5. Conclusion The fact is. Moisture Measurement And Part Quality Plastic dryers are used to remove moisture (water) that has been absorbed either onto the surface of plastic pallets or into the plastic pallets internal structure before they go into the injection molding machine to make parts. There are 2 groups of plastics. Plastic Dryers.75 at a cycle of 18.36 at a cycle time of 12.More importantly. 2. This is one benefit of fast cycling thin wall injection molding. Plastics with excess moisture levels will react when processed in the molding machine barrel and will produce by-products that will effect such things as impact strength in the finished molded part.0 seconds. Click here to learn more about the benefits of thin wall injection molding. the results show that the machine uses energy more efficiently at faster cycle times. Drying is required to ensure good quality parts are made consistently.
POLYURETHANE 12. Sensor based (usually Karl Fischer) are the most accurate because they will only measure the moisture level in the pallets. NYLON 13. This means you are not just wasting time producing rejects but more importantly are likely to damage your company’s reputation as a quality supplier. That’s why it is critical that the moisture content is measured before processing. POLYCARBONATE PET POLYESTER 10. 9. . This fact is very important to know so that moulders do not rely upon visual checks to ensure the quality of the molded part. There are 2 different systems of moisture measurement . Parts that look good are not necessarily strong enough to function properly. flow lines or surface defects in the molded part. the massed based systems will measure the moisture level along with other volatiles produced during the analysing process giving a false reading. their mechanical properties are not affected by moisture.8. Moisture Measurement Methods. The part will have reduced impact and tensile strength but will not show any cosmetic defects. PBT POLYESTER Plastics 1 to 7 need to be dried for cosmetic reasons only. Just because the plastic material is dried at the recommended temperature and length of time doesn’t mean the material is dry enough to process. Why It Is Important To Measure Moisture Level After Drying. Excess moisture in the plastics 8 to 13 will affect the mechanical properties in the molded part. PEI 11.massed based and sensor based instruments. This should be done on a daily basis so that moisture can be eliminated as a reason for any part quality issues. Processing plastic pallets in an injection molding machine that have not been dried to the required level can lead to disastrous consequences in the field. However. Excess moisture will cause bubbles. However. If the desiccant dryer has not been maintained properly then the plastic material may still have too much moisture and may need to be dried for a longer period of time.
Other cost requirements for medical device injection molding are for rapid prototyping equipment. In addition to this. Additional Comments As an injection moulder you spend millions of dollars in equipment such as molding machines. Medical Device Injection Molding The medical device injection molding process is used to produce parts because of it ability to produce large quantities with consistent quality and low unit costs. But these are not reasons to use this type of instruments because they do not give accurate and repeatable results. the ISO 13485:2003 quality management system certification is a requirement to do business with Australian. quality injection molding machinery. medical injection molding is not without its challenges and to be successful the following issues require serious consideration. However. What’s more. material cost is an injection moulders largest ongoing expense so it is critical that waste is eliminated. The certification costs tens of thousands of $US and takes several months to implement.standards. the range of plastic materials available for medical injection molding is large for both commodity materials such as PP and engineering materials such as PVC. Clean rooms are significantly more expensive to build compared with factory buildings in other plastic injection molding industries such as automotive. Medical injection molding requires a high degree of cleanliness so factory buildings with clean rooms are a necessity. part assembly and packaging take place inside a clean room. Annual ongoing audits and costs are required to maintain the certification. robotics. Japanese. The injection molding process. moulds and chillers so there is no excuse not to spend a bit more on quality plastic dryers and moisture measuring equipment.The appeal of massed based systems are their lower purchase price compared with sensor based and are easier to use. Click here to learn more http://www. On top of this. Medical injection molding also offers a large degree of freedom in part design so many different shapes and sizes can be produced. the 2 main benefits are: potential for more customer leads and improved efficiency within the organization.org/standards/listing/iso_13485 Despite all of the costs of the certification. American and European medical industries. . injection molds and equipment for the vast array of secondary operations. These are invaluable.
because molding machine technology and automation are constantly improving. solve problems when they arise and increases employee morale. Flexibility Because medical device designs are constantly being developed and improved.Training Because quality and costs are paramount. it is important that an injection molding company be able to adapt in order to maintain and build market share. it’s just as important to continually invest in new equipment in order to maintain competitiveness. project management will ensure good communication between all relevant people including toolmakers. rapid tooling. Project Management For any new product. Also. medical field experts and plastic suppliers. It encourages people to think for themselves. sla. 3D printing) Mould design Moulding machine process technology Moulding machine process monitoring Secondary operations (such as ultrasonic welding) Sanitation standards Quality standards Training will pay for itself many times over in the long term. employees must be properly trained in correct practices in the following areas: R&D Part design Plastic material selection (commodity and engineering materials) Rapid prototyping technology (sls. injection molders. . Bringing people together at the right times and in the right environment is the only way to have a good outcome. product designers.
Not only must they produce quality medical devices on time. but also must be able to add value to the devices by providing secondary operations. they must be involved in the development of any new medical device so any potential manufacturing pitfalls can be eliminated before the project is started. Just because a moulding machine can produce a clean looking part without flash it doesn’t mean the clamp is enough. If process parameters are not optimized then clamp tonnage will need to be higher than is necessary. Square & Rectangular Parts:(mm) Round Parts:(mm) . In addition to this. This is assuming that the process parameters have been setup correctly and optimized so that consistent fill times are maintained and hold pressure is not excessive. molders must provide a full range of services. For any particular part.Additional Comments To be successful in medical device injection molding. Clamp Tonnage Calculator Use the following clamp tonnage calculator to get an estimate of the tonnage required to mould a part. It has been validated with molds making containers for both thin wall and thick wall parts. there are a range of clamp tonnages than can produce parts that appear to be ok. This uses extra electrical energy and increases the rate of wear in the mould and machine. Machine Clamp Tonnage Calculator For Polypropylene. Correct Clamp Tonnage What is the right clamp tonnage for a mould producing a particular part? Getting the right clamp tonnage can be tricky. But what about the weight? The correct clamp tonnage will produce parts to the target weight consistently over an extended period of time.
size and wall thickness). weight. Choosing a screw without knowledge of the parts is like buying a car without any preference for performance and handling requirements. The basic mould design is also important so that flow length from gate.50 1.10 Number of Mold Cavities: Material Flow Index (MFI): 0 Number of Mold Cavities: Material Flow Index (MFI): 0 25 15 Answer: Metric Tons Answer: Metric Tons Selecting Injection Molding Screws Using the right injection molding screws is crucial to making quality parts consistently and with maximum production output.Length: Width: Max Flow Length From Gate: 0 Diameter: 0 0 0 Max Flow Length From Gate: 0 Wall Thickness: Wall Thickness: 0. shot weight and runner system are all taken into consideration. details of the particular part to be moulded must be known (that is. To select the right screw. Screw Design . part material.
2. This compression forces the pellets to melt through the action of pushing up against each other. As an example.The basic design of any screw has 3 zones along its length: 1. PE. There are many different designs of barrier screws. Nylon. In the transition zone the material is compressed by the change in the depth of the screw channels from the feed zone to the metering zone. PET and PC so they are very flexible and good for moulding companies that mould a variety of different materials. for some materials. the L/D ratio for PP and PE is in the range 20- When it comes to general purpose screws. Barrier Screws This type of screw provides a better quality melt at a faster rate compared with a GPS. 30:1. The exact design chosen must be in line with the application. The disadvantage is that. longer screws are usually preferred because they will produce a better quality melt and therefore produce better quality parts General Purpose Screws (GPS) The advantage of a GPS is that they can be used with most plastic materials such as PP. part quality and productivity rates will be lower compared to more advanced injection molding screw designs such as the barrier screw. The ratio of the change in depth is called the compression ratio and is usually between 2 and 3 for plastics such as PP and PE. 3. This is called shearing. the difference being in the varying of the flight depths and channel widths. The metering zone then conveys the melt to the front of the screw ready for injection into the mould cavity. Feed zone Transition zone Metering zone The feed zone conveys the solid plastic pellets which are fed from the hopper to the transition zone where they are compressed by a change in screw geometry. The length of the transition zone is typically 4 to 7 x the screw diameter in a general purpose screw. Double Flight Screws . Another aspect of screw design is the length to diameter ratio (L/D) meaning how long it is compared to its diameter.
Although double flight screws have a different design. not just because of the cost of the replacement screw but for the loss in production. Screw Diameter The screw diameter is important for 2 reasons. Wear Resistant Injection Molding Screws Serious thought should be given to using a heat-treated screw and barrel as these will provide longer life than non heat-treated parts. Initially it might seem advantageous to choose the largest diameter so that there is more flexibility in the types and size of parts that can be made in one machine but this is the wrong way to think about it. It can be seen that there is a conflict between shot size and injection pressure when selecting a screw diameter. . The design ensures the plastic is fully melted before it reaches the compression zone. which is not the case in a GPS. Once the screw and barrel start to wear. Double flight injection molding screws can be used in technical parts for PP and thin wall technical parts in PA which does not plasticize well with barrier screws. The injection unit must be capable of generating enough injection pressure (with some in reserve) to maintain consistent fill times and as a consequence. They are also designed to deliver a high quality melt at fast rates. the smaller the diameter the higher the available pressure. The second reason is the diameter determines the maximum shot size available. This is especially important when the material contains some level of reinforcement as this is much more abrasive and will wear out the screw and barrel sooner than material without reinforcement. This is critical for parts that have thin walls and a long flow length and for plastic materials that are difficult to inject. The smaller the diameter. maintain the quality. part quality will start to suffer and it will only be a matter of time before a replacement will be needed. The screw diameter should be chosen in line with the application otherwise quality and/or productivity rates will suffer. The first reason is that it determines the maximum available injection pressure. the smaller the shot size. Screw Tip The tip is a non-return valve at the front of the screw which allows the melt to pass through during the plasticizing stage but stops the melt from back flowing into the screw during the injection stage. This is a large cost. they are an alternative to barrier screws.
A proper design will ensure quality plastic parts will be produced for the intended life of the mould at the expected cycle time. in today’s competitive environment.A Little Known But Costly Mistake Correct injection mold design is crucial to having a profitable business. However. a ring check valve is suited to shear sensitive materials such PC. Click here to learn about another common design mistake.There are 2 basic designs the ball check valve and the sliding ring check valve. Using the right injection molding screws for your parts will play a significant role in this. many mold designs have some fundamental flaws which prevent the injection molder from achieving a higher level of productivity. Your question and my answer to it will then be part of this page for others to read. Additional Comments The fact is. the disadvantage of the ring valve is their tendency to wear. Therefore. Correct injection mold design has the following benefits: Quick mold setups Faster cycle times Quality parts Low reject rate High productivity Long mold life Long molding machine life Higher employee morale Unfortunately.Click here to learn about what makes a competent injection mold designer. The ring check valve is generally preferred because it allows an easier path for the melt to pass through compared to a ball check valve. If you have a question about mold design either scroll to the bottom of the page or click here to skip down to the form. By learning about one of the most common injection mold design mistakes you can avoid waste and help make your company grow and be more profitable. so the ring check valve condition should be checked on a regular basis. A typical sign of wear is inconsistent cushioning during processing. injection molding manufacturers need to be making parts as efficiently as possible in order to keep manufacturing costs down and delivery times short. . Injection Mold Design .
. What’s more. Figure 1 shows the back plates in between the molding machines platens. The back plates have 3 main functions: To hold the mold in the moulding machine using clamps To form part of the runner system Support the entire mould against excessive platen deflection If the back plates are too thin then the resultant repetitive deflection during each cycle eventually causes the following part quality problems: Flashing Shorting Weight variation Voids Sink Balancing issues These quality problems occur because the platens do not provide enough support to stabilize the mould against cavity injection pressure and clamp tonnage. Poor venting will also result in reject parts – especially in multi cavity moulds. repetitive deflection causes wear inside the mould.One of the Most Common Mistakes Thin Back Plates Most molds have 2 back plates with one on the fixed side and one on the moving side. One of the things mould wear does is reduce the effectiveness of the venting.
The diameter is quite large in most machines as it is clearance to allow the machine injection unit nozzle to connect to the mould (see figure 1). A cavity is naturally weak because of its shape. Platen deflection is usually worse on the fixed side platen because of the weakness created by the location ring diameter and the larger recess behind it. This can happen over a period of years. The combination of these 2 weaknesses require an extra thick back plate on the fixed side to strengthen a mold. The lid started to severely flash after only 8 weeks from mould commissioning. Figure 4 gives a closer view of the hard marks. if the deflection is extreme then part quality will deteriorate over time. The main clue to the problem was the pattern of radial brown hard marks found on the back plate – see figure 3. The thicker back plate bought the deflection within a manageable level so that quality problems were eliminated.It’s important to keep in mind that during the injection molding process most machines will have some amount of platen deflection. An investigation found that there was too much platen deflection so the fixed side back plate was replaced on the mold. . if the fixed half of a mold is a cavity (as opposed to a core) then this adds to the weakness of the system. This pattern was a clear indication of too much platen deflection causing the mould to wear on the shut off faces of the cores and cavities resulting in part flash. however. Case Study Figure 2 is a rectangular lid made from a 2 cavity mold. The original plate was 90mm (see figure 5) while the new plate was 150mm. On top of that. Platen deflection is not necessarily a bad thing. months or weeks depending upon the injection mold design and selection and condition of the moulding machine.
This type of issue happens in all types of injection moulds from fast cycling thin wall moulds to slow cycling single cavity moulds and the sign is the same for all of them. Figures 6. . 7 and 8 are more examples of the hard mark pattern produced when large platen deflection is present. Look for radial lines of hard marks on back plates and also on shut off surfaces of cores and cavities.Additional Comments Relating part quality problems to excessive platen deflection is not that difficult once you know where to look and what to look for.
Example of Good Injection Mold Design .
This is how the hard marks on a properly designed mould should be. . 10 and 11 show a 4 cavity lid mold designed with an extra thick back plate on the fixed side 150mm thick. This mould has produced millions of quality parts without any problems. Note the hard mark pattern on the back plate in figure 9. it is completely different to the pattern in the 2 cavity (figure 3).Figures 9.
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