Controlling the way molten plastic fills and cools in a plastic injection mold to form a part is an evolving science. Youthful companies are injecting new energy into this industry all the time, to improve the quality and accuracy of molds that in turn will enhance the usefulness of parts being made. Dividing the part to be built into basic groups helps minimize molding problems and improve accuracy.
Plastic injection molds are used for making all kinds of components for everything from aerospace to consumer electronics. The process can produce parts with holes, springs, threads, hinges and other finely defined uses. Sophisticated tooling can be rendered accurately to 100th of a millimeter. Parts can be as simple as a toothbrush or set of nails or as complex as a lipstick or laparoscopic surgical instrument.
Whether flexible or rigid, small or large, objects made through a plastic injection mold are generally flawless. The products can also be textured, polished, plated or colored. The range and capability of the process is matchless. Customized machines of all sizes manufacture multiple products that we use on a daily basis and parts for use in specialized applications.
Integral to all industries, the process begins with heating thermoplastics to the temperature best suited for its application. Frictional heat and external heating bands convert dry materials into molten plastic. This is injected into a plastic injection mold at high speed, with pressure. Inside the mold, the molten plastic cools and solidifies to form the part. Depending on the scale and complexity of the part, the system is either highly automated or involves human interaction.
Accurate Plastic Injection Mold
Finely tuned measuring devices exist in the process, to form for example, a foam cup and its tightly-fitting plastic lid. Lego is another example of a precision product available in many colors, shapes and sizes and made purely with plastic injection mold. Today there is outstanding software that allows precise measurement of 3D objects. This technology is widely used to measure surface and form profiles for enhanced accuracy.
Dimensions of components need to be precise to prevent faults from occurring when the part is in use. For example micro gear drives used extensively in motor vehicles and household appliances can be troublesome if not accurately made. Automatically identifying potential flaws and faults using specialized measuring devices allows for improvements to the part during the development process. The plastic injection molds created using these measurements can be optimized and corrected.
Highly sophisticated measuring devices detect the inner geometry of injection mold parts. Surface inspection can be performed in a non-destructive way. Components of every type can be measured in their full form through 360 degrees of rotation. By detecting typical component errors, plastic injection molds can ensure repeatability with remarkable accuracy.