Mould Design & Tooling

In the plastic manufacturing industry, the durability and longevity of a plastic injection mould or mold are crucial for efficient production. Injection mold life expectancy can range from less than 500 cycles to over 1 million depending on aspects like the quality of the mould and the material being moulded. Understanding the lifespan of these moulds can help plastic manufacturers plan for maintenance and replacements as well as allowing them to anticipate production capabilities. In this article, we’ll explore how long plastic injection moulds are expected to last and the factors that can contribute to their longevity.

How Do Injection Molds Wear Out? 

From material selection to working environments, several factors can affect the durability and longevity of plastic injection moulds. 

Plastic Injection Mould Material 

The materials used for both the mould and the plastic being shaped play a big role in how long the mould lasts. Steel molds for plastic injection are a common choice for their durability in high-volume production and can exceed one million cycles.  Aluminium moulds for plastic injection are cheaper but they wear out faster making them suitable for low-volume production.

The type of thermoplastics used during manufacturing also matters as some plastics are more abrasive than others. Corrosive resins like PVC for example can damage aluminium moulds.

Plastic Injection Mould Design and Construction

A well-designed and precisely constructed mould will last longer. This is why investing in high-quality engineering is crucial. Higher-quality moulds have a much longer tool life and can last as long as 100,00 cycles. Complex moulds can be more susceptible to wear and may require more maintenance due to their intricate parts. The way the components within the tool are arranged and the overall mould design can also dictate how long the mould will last. 

Plastic injection Mould Maintenance

Poorly maintained moulds not only cause defects and production delays but also significantly shorten the mould’s lifespan. This is why regular maintenance practices such as cleaning, lubricating, and inspecting are essential. With regular inspections, you can help identify any early signs of damage and extend the injection mould life expectancy with a minor repair. 

Production Volume

The number of cycles plastic injection mould tools are put through directly impacts their longevity. High production volumes mean more frequent use, which accelerates wear and tear. Manufacturers should ensure their production demands are combined with increased mould maintenance to avoid overworking the moulds and compromising their durability.

Operational Conditions

Plastic injection moulding operational conditions, including injection pressures, temperatures, and cycle times, also affect mould lifespan. High pressures and extreme temperatures can cause stress on the mould materials, while fast cycle times and increased production speed can also increase the rate of wear. By adjusting these parameters to optimal levels, manufacturers can help prolong the mould longevity.

How Long Does An Injection Mold Last? 

Injection moulding tools can have varied life expectancies depending on the factors mentioned and the injection moulding plastic materials. Here are some general estimates for different types of moulds and production volume levels.

• Prototype Moulds –  These typically last for a few hundred to a few thousand cycles and are used for low-volume production or testing.
• Medium production moulds – These moulds are built for medium production volumes and can last around 500,000 cycles
• High-Production Moulds – Usually made from hardened steel, these moulds can last for over a million cycles if properly maintained.

Plastic Injection Moulds from Fern Plastic

When it comes to effective plastic manufacturing, a well-designed and maintained plastic injection mould is essential. At Fern Plastics we offer plastic injection mould services that ensure your moulds are durable and efficient. Whether you need new moulds, repairs and maintenance or reshoring support for mould transfers, we can help. 

For more information about our plastic injection mould manufacturing, contact us online or call 01902 758282.

When it comes to manufacturing quality plastic injection moulded products, we are experts in our field. From the smallest, intricate part to large, mass-produced plastic moulded projects, we have experience and skills to perfect your products. When it comes to plastic injection moulding, there will always be risks of defects in the finished product. Here are just some of the ways we avoid injection molding defects in our injection moulding process using high-tech machinery and skills to create your perfect product.

Avoiding Air Pockets and Vacuum Voids During the Plastic Injection Moulding Process

When creating bespoke products using plastic injection moulding, it is extremely important to avoid the creation of air pockets during the process. A bubble defect in injection molding can be the result of volatiles from the resin, the decomposition of gases from polymers or additives or moisture vapour. This can inadvertently distort the shape and use of the finished product. As experts in our field, we have a number of processes in place to avoid this in our plastics mould manufacturing process. We also have high-tech machinery to optimise the process and ensure adequate moulding pressure forces any excess air out of the moulding cavity. Our high-tech plastic injection moulding machinery also ensures premature cooling does not happen, another cause of air pockets in the moulding process.

Preventing Burn Marks in Our Plastic Injection Moulding Process

In some cases when creating plastic injection moulded products, burning can appear. In many cases, this can be due to air or even resin becoming trapped in an air cavity and overheating. This then results in the scorched material. Here at Fern Plastics, our skilled team members prevent burn marks in injection molding by loosely monitoring the temperature of our plastic injection mouldings and the speed of our injection mouldings to ensure this doesn’t happen to our products. We take pride in ensuring each of the products that leave us are fit for purpose and look visually as expected..

Avoiding Plastic Injection Mould Warping

As with any materials, when treating plastics and using them during the plastic injection moulding process, there is a risk of warping the materials. A warping defect in injection molding has a range of side effects including excessive space produced between components and misshaped products. Warping as an effect of the injection moulding process can be caused during the cooling process when uneven shrinkage can put stress on different parts of the plastic product. Often, the materials used can be prone to developing warping defects. Materials with semi-crystalline structures are more likely to be subject to warping. We combat this through strategic selection of materials and expert mould design to avoid this. We also ensure an even and gradual cooling process to avoid warping of the plastic injection moulded product.

Jetting During the Plastic Moulding Process

A jetting defect in injection molding can occur when the solidification process happens unevenly. In order to create a smooth, streamlined plastic injection moulding without any jetting, it is important to use the perfect injection pressure for your product to avoid initial streams solidifying before the product is finished. We have years of experience perfecting the plastic injection moulding process so make it our priority to provide an exceptional product and service each and every time. Our innovative machinery calculates the exact pressure needed for every moulding whilst our mould designs optimise for a smooth finish.

Preventing Sink Marks in Injection Molding

Sink marks are common defects in injection moulding often found in thick-walled sections. One of the main causes of sink mark defects relates to incorrect melt temperatures. We are able to prevent the formation of this defect by understanding the importance of staying within the temperature range recommended by the resin manufacturer. Since thick sections contain more plastic, failing to verify the temperature can result in the part taking longer to cool which will lead to the formation of sink marks. As well as verifying the correct temperature during the injection moulding process, we make sure the correct second-stage pressure and pack and hold times are maintained. The ideal second-stage pressure (or pack and hold pressure) not only helps to prevent shrinkage but when combined with the proper pack and hold times, ensures the part is efficiently sealed which can prevent sink marks from forming. Where applicable, we apply gas-assist injection moulding processes to help reduce the appearance of sink marks.

Avoiding Short Shots in Injection Molding

During the injection molding process, partially formed parts known as short shots occur when the resin hasn’t entirely filled the mold cavity. The result is a plastic part that is visibly incomplete and often unusable. We prevent short shots in injection molding by ensuring a consistent flow within the mold cavity which can be affected by blocked or narrowed gates. We also avoid short shots by adjusting the mold temperature and maintaining the correct injection pressure so that the entire mold cavity is filled during mould injection. 

Weld Lines in Injection Molding

A weld line defect is formed when two flows of injected resin material meet within the mould cavity. Also called a “knit line”, these marks usually form around holes as the plastic flows around either side. When the temperature of the resin is incorrect, the two flows fail to bond together properly which results in a visible weld line. Weld line defects reduce the durability, strength and aesthetic quality of the plastic component. To combat the formation of a weld line defect in injection molding, we can make adjustments to the mould design as well as raise the temperature of the molten resin which prevents it from solidifying too fast. Low-viscosity resins with lower melting points are often less prone to developing weld line defects. We also adjust the injection speed and pressure where necessary which also prevents early solidification and the formation of knit lines. 

Our experienced and highly trained team are fully equipped to deal with the nuances of plastic injection moulding to ensure an industry-leading product each and every time. If you are looking for state-of-the-art plastic injection mouldings from a source you can trust, get in touch with the team here at Fern Plastics and find out more about what we can offer you. Get in touch online or call 01902 758282 for more.

The process of plastic injection moulding is a fantastic way to produce high quantities of perfectly replicated products for a relatively low cost. At Fern Plastics, we have been specialists in plastic injection moulding for a number of years so know how to get the very best out of the process. We always assign a project manager to each of our plastic injection mould projects to ensure they are the most effective moulded projects they can be. Here’s why we think having a project manager for plastic injection moulding is a key part of our success.

Coordinated and Coherent Injection Moulding Management

We know that every project is important when it comes to plastic injection moulding, that’s why we only work with skilled and experienced individuals we know will get the job done right the first time. Our fully-trained, qualified and experienced plastic injection moulding specialists will involve themselves in your project from the first inception to the final finished product to ensure it is effective and as promised. Our injection moulding project managers have seen every challenge our customers face and know the best ways to get the most out of the plastic injection moulding process so are perfectly placed to advise and answer any questions you may have.

Effective Products

We know that no two projects are the same with each product offering a unique set of challenges and needs. Your dedicated project manager will work to understand every requirement and use of your plastic injection mould to ensure an effective product every time. Our fully-equipped in-house tool room provides the perfect space for the manufacture, repair and modification of mould tools, gauges, jigs and fixtures to keep them fit for purpose with a team of specialists on board to make your project a success,

What Our Plastic Injection Moulding Specialists Provide

Our experienced and fully-trained project managers can offer design failure mode and effects analysis (DFMEA) and Advanced Product Quality Planning (APQP) to full Production Part Approval processes (PPAP) along with CAD and mould flow analysis to assist with product and mould tool design to ensure your plastic injection moulded product can meet whatever demands are thrown at it.

Our unique long-standing relationships with a selection of low-cost economy tool makers also ensure that projects are completed on-budget. With knowledge of each of the specialist services we supply here at Fern Plastics, your plastic injection moulding project manager is perfectly placed to advise on every aspect of our business and your project to ensure it is the best it can be and performs as efficiently as possible.

Specialist Services and Advice for Every Project

If you are looking for a specialist plastic injection moulding service with a difference, Fern Plastics are here to help. Our knowledgeable team have created injection moulds for a wide range of industries and uses from medical tools to car parts, toys and everything in-between and are committed to fast, reliable service to fit your budget.

To find out more about our plastic injection moulding service, contact Fern Plastics now online or by calling 01902 758282.