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Successful Injection Molding BusinessIn the injection molding business, design engineers follow five simple rules. They don’t have to be experts in fluid dynamics to be able to produce successful injection-molding plastic parts.
Any kind of plastics have fluid content. Therefore, they are all controlled by the laws of fluid dynamics. In order to produce molded plastics that you need, you have to understand the flow of plastics that occurs during the injection molding process. Since many design engineers cannot calculate all the movements of plastics, manufacture drawbacks could occur.
Because of these potential production problems, design engineers came up with these three guidelines to prevent wasting production money and being able to provide the plastic parts to your clients without delay. The most important thing to consider in this business is designing the injection-molded plastic parts. Follow these rules and guarantee your products will end up as you planned.
1) Wall Thickness should always be Consistent – The most important rule in design is making sure that the walls of your plastic parts should have uniform thickness. If you strict to this rule at all times, it immediately eliminated many potential manufacturing drawbacks.
Parts that have uniform walls do not warp, shrink or break out. As a rule of thumb, wall thickness variations should never exceed ten percent. Be aware that even the slightest disparity could lead to quality and processing problems.
If you cannot avoid varying wall thickness, you should provide the most appropriate gate location. According to experts, the most effective gate location should be where the melt enters (usually at the thickest part of the cavity).
2) Determine the most appropriate wall thickness – According to experts, there are no maximum wall thickness measurements for any kind of injection-molded parts. However, many designers go for the thinnest walls because these are more inexpensive. There are two advantages in using thin walls – first, the plastics cool faster and second, thin parts need fewer plastic materials.
In determining wall thickness, don’t simply go for the cheapest materials. Instead, consider your product requirements in deciding wall thickness.
3) Provide generous radius corners – In the middle of the injection molding, the melted plastics have to navigate corners. Usually, rounded corners tend to ease the flow of plastics while sharp corners give stress to the plastics during the cooling process. For this reason, you should always keep generous radius for all corners of the parts.
By following these basic rules in design, you can guarantee that the plastics will match your specifications every time. Thus, saving costs and generating more income.
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