Plastic Injection Molding Service
If you need online injection molding we are one of the most capable and affordable and we can get the job done right.We stock a wide variety of materials, use state-of-the-art machines and diligently follow all design specifications. We continually strive to improve and optimize our processes and maximize customer convenience. Our customers range from inventors to businesses to government agencies. We are focused on quality and customer service.
How plastic injection molding works ?
Injection molding produces parts by forcing molten plastic into a mold where it cools and hardens. Granular plastic is fed by gravity from a hopper into a heated barrel. As the granules are moved forward by a screw-type plunger, the plastic is forced into a heating chamber, where it is melted. As the plunger advances further, the melted plastic is forced through a nozzle into the mold cavity. The mold remains relatively cold so the plastic solidifies almost as soon as the mold is filled. Custom steel tooling is required and adds to the initial cost but is quickly amortized.
Injection molding provides low cost at moderate to large quantities. This method of making plastic parts is an extremely versatile process for producing a wide range of parts with an excellent finish. Almost any 2D or 3D shape can be achieved. However draft is required in most cases as the shape must allow ejection from the mold. Side holes and even threaded holes are possible though they complicate the tooling.
Advantages Of Plastic Injection Molding
Among the many advantages of plastic injection molding are the following:
- Thousands of plastic resins to choose from for any application
- Most cost-effective way to make large volumes of parts fast
- A single tool can last for up to millions of cycles
- Excellent surface quality and dimensional characteristics can be achieved
- Different plastics can be overmolded for even more design options
- The process is stable and reliable for predictable results
The following terms are commonly used for this manufacturing process:
Step 1. Ejection pins are rods that push the part out of the mold.
Step 2. The gate is the location where plastic is injected.
Step 3. The parting line is the location where the two mold halves meet – a thin line will appear at this location.
Step 4. A living hinge is a thin connection provided between two sections of a molded part so that it can be used as a hinge, e.g. a box, with a lid, molded as one piece.
Step 5. Insert molding is where a rigid part is inserted into the cavity prior to injection – a screw driver with a plastic handle is an example of insert molding.
Step 6. How material will shrink, thereby effecting the accuracy and uniformity of your part after it cools. Where the shape is thickest it will shrink the most. For example, in a 5 sided box with internal cylindrical posts for mounting a circuit board, you may see slight recess dimples on the outside of the box underneath where the posts occur as the posts will tent to pull the material in slightly
A tolerance is the measurement — usually calculated in fractions of an inch — specifying how much a given feature of a part may deviate from the specified measurement. For example, if an injection molded part is specified to be 1 in. long with a tolerance of 0.1 in., completed parts between 0.9 in. and 1.1 in. long would be acceptable; completed parts that are 0.89 in. or shorter or 1.11 in. or longer would not be acceptable.
Tolerances are set to ensure the proper performance of your part; parts out of tolerance can cause any number of issues in their end application. Tolerances can also vary depending on materials and processing methods.
Because of this, designing a part and selecting its material and production method can be a challenging process.
Plastic Injection Molding Materials
We manufacture injection moulds and dies from aluminum 7075, P20 and NAK80 semi hardened steel and H13 completely hardened steel. In addition, we provide standard SPI finish, EDM texture and etch texture range.
How to choose the material type? The following are the consideratons for each material has advantages of its own:
- Cost of the raw material
- Durability and resistance to corrosion or abrasion
- Ability to take a high surface polish
- Time required for heat treatment
- Expected tool life
Plastic Injected Parts
Ares Mould is a full-service plastic injection parts manufacturer providing prototyping, manufacturing and assembly. We have the technical know-how to build the most complicated tooling using the broadest range of injection molding plastic resins, including commodity, engineering and high-performance grade resins.
A full-service partner, we are uniquely equipped to offer prototyping, manufacturing, assembly and value-added services for virtually any size part. We provide plastic molding expertise for short to large runs. Diversified Plastics delivers:
- Design and product development assistant to maximize the process
- Machined prototype parts
- Complicated prototype tools
- Tool shop on-site
- Close-tolerance plastic injection molding
- Filled materials, insert molding and over molding
- Clean Room assembly
Once you send us a 3D CAD file, our engineers will review draft angles, wall thickness, corner angles, material type and more to ensure it is optimized for manufacturing. We will also make sure correct materials are combined with the correct design considerations so your project meets and exceeds your expectations. Contact us today for your free quote.