Injection molding is a manufacturing process that has been around for over 100 years. It was first used to produce soap and later evolved into injection molding machines, which are now used to create almost anything you can imagine, from the battery in your phone to running shoes. This article will cover everything you need to know about this fast, efficient manufacturing method.
Common Applications of Injection Molding
The injection molding process is used to create components for a wide variety of products. The most common applications include automotive, electronics, medical devices, and many more.
- Fiberoptic– Injection molding is used to manufacture connectors and parts for fiber optic applications in the telecom and medical industries.
- Electronics– Circuit boards, connectors, and other electronic devices are manufactured by injection molding.
- Medical– Injection molding is used to create medical devices, such as syringes and airways.
- Aerospace/Aviation– When dealing with the harsh and isolated elements found in the aerospace industry, precision is essential. Injection molding is often used to design and manufacture high strength and lightweight components for planes and spacecraft.
- Consumer Products– From toys to textiles, QT Manufacturing utilizes CAD/CAM technology to produce original molds or reverse-engineer molds for your legacy products.
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The Injection Molding Process
In injection molding, a machine called an injection unit injects molten material into a heated cavity. The injection unit is made up of three major components: injection, hopper, and clamping tools. The tool uses a CAM to open the mold at just the right time so that molten plastic can be injected into it. This occurs when the two halves of the mold are brought together under pressure with pre-compressed air. The injection unit then moves the part out of the mold and into a cooling area, where it solidifies. The clamping tool holds the mold shut while the injection and ejection processes are taking place.
Injection Molding Machines
There are three main types of injection molding machines: horizontal, vertical, and rotary. These injection molding machines can be used to produce both simple and complex parts.
Horizontal Injection Molding Machine
The injection unit is horizontal, which means that the molten plastic enters into one end of a heated cavity. A second injection head injects more plastic at high pressure once the first has emptied out. Horizontal injection molding machines can produce large, high-quality injection molded parts at a low cost.
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Vertical Injection Molding Machine
The injection unit is vertical and the molten plastic enters into one end of a heated cavity. A second injection head injects more plastic once the first has emptied out. Vertical injection molding machines can also be used to manufacture large injection molded parts, but are typically more expensive.
Rotary Injection Molding Machine
The injection unit is rotary and the molten plastic enters into a heated cavity that slowly rotates around an axis. This type of injection molding machine is used to produce small, complex injection molded parts with high precision and quality.
Advantages of Injection Molding
There are several advantages associated with injection molding. These include:
- Speed – Injection molds can be created in a matter of hours instead of days or weeks like other manufacturing processes.
- Accuracy – Parts are manufactured with high accuracy and consistency.
- Cost – Reduce manufacturing costs and realize economies of scale by creating large batches and lot sizes.
- Versatility – Fabricate a wide variety of products, from simple to complex.
QT Manufacturing offers turnkey solutions with industry-leading injection molding equipment and capabilities to keep up with the demand of your products or business needs.
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Injection Molding Services in Dallas, TX
With over 30 years of injection molding experience, QT Manufacturing is your go-to source for high-quality injection molded parts. Our shop is ISO9001:2015 and AS9100D rev D certified and equipped with the latest equipment and technology to produce parts that meet your exact specifications. In addition, our team of experts will work with you to ensure that your injection molded parts are perfect every time. Contact us today for a free quote at 972-221-0537 or to learn more about our services.
