With the continuous advancement of the Industry 4.0 strategy in Western countries and the Made in China 2025 strategy, scientific injection molding is also gradually emerging. Although the concept of scientific injection molding has been mentioned for some years, only a few companies can practice scientific injection molding. In this blog, you will get a comprehensive understanding of scientific injection molding and its 7 important steps and points of attention in practice.
What is Scientific Molding
Scientific molding is an advanced systematic molding method. It integrates and configures injection molding related resources scientifically and reasonably, utilizes the principle of molding process parameter control, and realizes the unity of product process and product quality with the help of advanced technology, to achieve a faster molding cycle, higher yield, and more robust molding process. This optimal control of injection molding is mainly concerned with the dynamic process of plastic in the mold, rather than the injection molding machine.
The concept of scientific molding: Do not try to solve all problems by process parameters, but be oriented to minimize or even not adjust the machine. Integrate resource allocation with the process flow to achieve high efficiency, low consumption, and high-quality production.
Traditional Molding vs. Scientific Molding
Scientific injection molding, unlike the traditional injection molding process, is concerned with the state of the plastic inside the mold cavity during the injection molding process, not just the parameters on the control panel of the injection molding machine. It is a practice to optimize the injection molding process to achieve faster molding over the same period, higher yields, and a more robust molding process.
Traditional injection molding:
- Mainly relies on people
- Analyze problems by experience
- Poor substitutability and repeatability
- Process lacks robustness
- Low efficiency and high overall cost
- Can solve some difficult problems
Scientific injection molding:
- Relies heavily on procedures, needs to train staff
- Analyzing problems relies on data
- Substitutability and repeatability are good
- Process is robust
- High efficiency and low overall cost
- Addresses most common defects
Scientific injection molding solves problems through quantitative means, which can reduce the number of mold changes and mold trials, help establish a robust molding process, reduce the defective rate of products, shorten the molding cycle, improve production efficiency, analyze problems with a systematic approach to reduce the dependence on people and experience, and help manufacturers to take the road of “high quality, high efficiency, and low consumption”.
Steps in the Scientific Molding Process
These are the 7 steps of scientific injection molding, these steps can not only help manufacturers to ensure product quality and production efficiency but also reduce costs and waste of resources
Step 1: Designing the right mold
The first step in the science of injection molding is to design and build a suitable set of molds, or to check the availability of existing molds. The design of the mold should take into account the accuracy, size, and structural requirements needed for injection molding, and should minimize production costs without adding unnecessary complexity and cost.
Step 2: Prepare the injection molding machine
Before injection molding, it is important to ensure that the injection molding machine is in tip-top shape. This includes cleaning the machine, checking the various pieces of equipment, balancing the flow of the melt, and adjusting the temperature to ensure accurate injection molding.
Step 3: Prepare the material
The ingredients used in the injection molding process must be carefully configured. This includes selecting the correct plastic material, setting up and maintaining dryers, and accurately weighing and mixing the various ingredients.
Step 4: Start the injection molding machine
Once the machine, mold, and material are ready, injection molding can begin. This includes adjusting the injection molding equipment according to predetermined machine parameters, setting up predetermined injection parameters, starting up the injection molding machine, and preheating the mold for injection molding.
Step 5: Injection Molding Process
The key to injection molding is the precise injection process, which includes steps such as melting the plastic material, precise injection and cooling. This process needs to be closely monitored and controlled to ensure the quality and precision of the final product.
Step 6: Reburrs from molded parts
When the injection molding process is complete, the molded parts need to be removed burrs using the equipment associated with the injection molding machine. This includes opening the mold and releasing the molded parts, using a cooling system and a suction tool to cool and remove residue.
Step 7: Inspection and Correction
Finally, inspections and corrections are carried out to ensure that the product meets the desired quality standards, which can be done using a variety of advanced technologies, such as the use of optical and machine vision imaging, as well as measurement methods such as pressure and force sensors.
Key Principles in Scientific Molding
- Comprehensive understanding of material properties
Scientific molding begins with a detailed exploration of the material to be molded. This includes understanding the material’s flow characteristics, thermal behavior, and other properties that influence its molding behavior.
- Continuous monitoring and analysis of process data
In scientific molding, data collection is not just a formality; it’s a central practice. Parameters such as temperature, pressure, and cycle times are continually monitored and analyzed. This data-driven approach allows for precise adjustments to optimize the molding process.
- Optimized Processing Conditions
Consistency is key in scientific molding. This principle involves maintaining control over various processing parameters, such as temperature settings, pressure profiles, and injection speeds. This ensures a stable and reproducible molding environment.
- Optimized Tool and Mold Design
Explanation: The design of the mold is critical in scientific molding. Precision in tool design, including considerations for cooling, gating, and venting, ensures even material distribution and efficient part ejection.
- Continuous evaluation and adjustment during production
Unlike traditional molding processes, where adjustments may be made infrequently, scientific molding involves real-time monitoring. Operators can make immediate adjustments based on the monitored data to maintain optimal processing conditions, contributing to the consistency of the final product.
Conclusion
Scientific Molding is a systematic and comprehensive approach to improving production efficiencies, cost structures, and capacity that enables manufacturers to compete on a global scale.
Implementing scientific molding practices has equipped Midland with the ability to provide quality products and cost savings to our customers. By utilizing highly advanced technologies and processes, we are able to produce parts more efficiently while reducing product failure rates.
