Applying scientific injection molding principles to the manufacturing process will help optimize part design and robust mold design. This enables the development of optimal injection molding process conditions and maximum consistency in the quality of injection molded parts. This article will introduce three simple ways of scientific injection molding.
1. Simulation of scientific injection molding
Before designing a mold, a comprehensive evaluation of the part design is required. One of the most effective methods here is to combine the scientific injection molding process with mold flow simulation on the part to help determine mold specifications. This process is called a Design of Experiment (DOE) simulation, and it focuses on fill, warpage, shrinkage, and cooling analysis.
The virtual DOE simulation can be repeated as many times as needed, each time applying different variables to see how the part will be affected during the molding process. The simulated process will focus on any design flaws and determine the ideal gate location, which will help enhance part design and mold design rationale. In general, the data obtained in the previous process will help us determine the design and specifications of the mold.
For complex parts with tight tolerances, thin walls or multiple cores, scientific injection molding is the key to ensuring part compliance. Incorporating more scientific methods and tools in advance will help ensure that injection molding companies build the best set of molds from the start.
2. The use of scientific injection sensors
Mold makers can also implement scientific injection molding with pressure and temperature sensors for further scientific analysis. The data collected by the in-mold sensors will allow engineers to “see” what’s going on inside the mold while it’s running, and provide real-time feedback, allowing the injection molding machine to provide real-time compensation. This instant feedback enables process engineers to adjust each injection cycle in real time to improve overall part quality.
Without the use of a scientific injection molding process, molds are more prone to defects, delaying time-to-market and reducing overall part quality.
3. Scientific injection molding can save costs
With some additional technology, analysis, and upfront costs, manufacturers can save money in the long run. An optimized part and a well-designed and built mold can make everything easier in the production process, and the long-term return on investment can be substantial. The use of scientific injection molding technology can eliminate the generation of defects, shorten the injection molding cycle, and speed up the time-to-market of parts.
As one of the best injection molding manufacturers in China, Zhongde (Beijing) Machinery Equipment., Ltd provides high-quality, low-cost plastic and rubber injection molding parts to global customers. Zhongde’s scientific injection molding process helps you reduce design risks, with the support of many senior project managers and engineering experts, communicate in all project stages from design to production, and cut the costs to the bone, if you need injection molding services, welcome to consult Zhongde.