Plastic Injection Moulding News

Ever wondered how the countless plastic parts in your everyday life are made? From your phone case to your car’s dashboard, plastic injection moulding is a powerful manufacturing process that shapes molten plastic into precise and consistent end products.

In this guide we’ll dive into the world of injection moulding and explain:

• What it is and how it works
• The benefits it offers
• The wide range of applications

What is Injection Moulding?

Injection moulding takes plastic pellets and transforms them into solid plastic products using a specialised injection moulding machine. The plastic injection moulding process is broken down into the following steps:

Thermoplastic Material Selection

The process starts with choosing the right plastic type (resin) based on factors like strength, flexibility, and heat resistance.

Melting and Injection

The chosen plastic resin is melted until it becomes mouldable. Then, it’s injected into a precisely designed mould under high pressure.

Cooling and Solidification

The molten plastic cools and hardens within the mould, taking on the mould’s shape.

Ejecting the Part

Once solidified, the finished plastic part is ejected from the mould, and ready for use. At this stage, plastic waste from this process can be recycled to create a circular plastic injection moulding process.

What are the Advantages of Injection Moulding?

Injection moulding offers several advantages that make it a preferred manufacturing method:

• High precision and consistency – Produces identical parts with minimal variations, ideal for applications requiring exact fits.
• Design flexibility – Moulds can be customised to create complex shapes and integrate various features into a single part.
• High-volume production – Enables the creation of large quantities of parts quickly and cost-effectively.
• Minimal waste – Modern processes minimise leftover plastic, promoting sustainability. At Fern Plastics we aim to reuse and recycle up to 100% of our plastic and manufacturing waste to be used for future projects with the help of our in-house machines and recycling partners. Our processes mean minimal waste without any compromise on quality.
• Reduced finishing – Injection moulded parts often require minimal finishing due to the detailed nature of the moulds.
• Wide range of materials – A variety of plastic resins are available to suit different product needs.

Applications of Injection Moulded Products

The versatility of injection moulding extends to a vast array of products you may come across daily. Some examples include:

• Automotive parts – From dashboards and cup holders to intricate gear parts.
• Medical devices – Sterile syringes, medication trays and various medical tools.
• Consumer goods – Bottle caps, phone cases, toys, storage containers and more.
• Electronic components – Casings, buttons, switches and internal components.

Why Choose Fern Plastics for Plastic Injection Moulding?

At Fern Plastics, we offer a high-quality injection moulding service with over 60 years of experience. When it comes to choosing the right plastic injection moulding company, we go beyond basic plastic manufacturing. Our team ensure consistent and high-quality parts for any project, no matter the complexity. As specialists, we are also equipped to handle demanding specifications like leak-proof and pressure-tight designs. We also provide close dimensional tolerances with excellent surface finishes, fire retardant mouldings, transparent moulding or lenses as well as a range of value-added services. For peace of mind, we can guarantee your plastic injection mouldings will be correct and on time every time with 24-hour production.

If you are looking for a dedicated plastic injection moulding service with years of experience and expertise, get in touch with the team here at Fern Plastics. Contact us today to find out more about how we can help you and the range of services we provide.

FAQs

What plastic is used in injection moulding?

Injection moulding relies on a specific type of plastic – thermoplastics. There are hundreds of options available, but some of the most popular choices include:

• Acrylonitrile Butadiene Styrene (ABS)
• Nylon/ Polyamide (PA)
• Polycarbonate (PC)
• Polycarbonate Acrylonitrile Butadiene Styrene (PC+ABS)

What is made from plastic injection molding?

Plastic injection moulding touches almost every aspect of our daily lives. Here are some examples of products using this process:

Automotive Parts:

• Interior trim
• Dashboard panels
• Door handles
• Bumpers

Consumer Goods:

• Toys
• Kitchen utensils
• Containers
• Electronic housings

Medical Devices:

• Syringes
• Tubing
• Surgical instruments
• Pill dispensers

Packaging:

• Plastic bottles
• Caps
• Containers
• Packaging components

Electronics:

• Enclosures
• Cases
• Connectors
• Housings for smartphones, computers, and appliances

Aerospace and Defense:

• Components for aircraft interiors
• Military equipment
• Aerospace applications

Can all plastics be injection molded?

No, not all plastics can be injection molded. The process works best with thermoplastics, which can be melted and re-solidified. Thermoset plastics, which permanently harden when formed, are not suitable for injection moulding.

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As the demand for plastic products continues to rise, plastic manufacturers face increasing pressure to enhance their operational efficiency to stay competitive. Efficient operations play a crucial role in reducing costs, improving product quality, and meeting the ever-growing consumer demand. If you’re exploring plastic manufacturing services, understanding the latest techniques is crucial for achieving superior product quality. As an expert injection moulding company, here are a few of the techniques we implement to enhance our plastic manufacturing processes.

Optimise Injection Moulding Processes

Injection moulding is often at the heart of plastic manufacturing and when it comes to optimising plastic manufacturing processes, it’s best to take a systematic approach. 

The first step is the initial functionality testing and examinations. The mechanical functionality of moulding tools is thoroughly evaluated to ensure alignment with thermoplastic settings. Additionally, procedures like short shot testing focus on assessing issues like dynamic pressure loss and cavity imbalances in multiple-cavity tools.

Engineers then observe pressure curves and sample weight to determine the effectiveness of gate seals and identify sealing points during the moulding process. 

Next, sample parts are evaluated and defects are examined and recorded. Any recommendations for necessary adjustments to the process and the tool are documented while information about melt temperatures, fill time, tool temperature, coolant flow, cycle time, and pressure curves, is recorded.

At this stage of the process, the sample parts undergo rigorous quality control examinations which include assessing measurements and overall quality documentation. Any necessary tool adjustments are made based on the findings from the quality control phase and new sample parts are made if needed. The newly adjusted sample parts undergo the same quality testing procedures, with further adjustments made as needed.

To ensure the best results, the testing and adjustment process is continued until all process parameters meet the designated performance ranges.

Utilise Gas Assist Injection Molding

The type of plastic manufacturing process applied can also help create a superior plastic product. Gas assist injection molding takes precision to the next level by introducing nitrogen gas into the mold cavity. This innovative technique not only strengthens complex parts but also eliminates cosmetic defects like sink marks and surface irregularities. The lightweight yet robust components produced through gas-assist injection molding offer a winning combination of structural integrity and impeccable surface finishes, meeting the highest standards for your end product.

Enhance the Thermoplastic Material Selection

Selecting appropriate molding material is a crucial factor in enhancing the overall plastic manufacturing process. Proper material selection goes beyond meeting the basic structural requirements of a design. Choosing the right high-performance polymers is a strategic decision that influences the efficiency, cost-effectiveness, and quality of the entire production cycle. 

By carefully considering factors such as material flow characteristics, shrinkage rates, heat resistance, and chemical resilience, plastic manufacturers can tailor their selection to match the unique demands of each project. This precision in the thermoplastic material selection ensures the seamless functionality of the plastic manufacturing process. Additionally, careful material selection contributes to the production of high-quality, durable, and precisely engineered plastic parts.

Invest in Advanced Injection Mold Design

In the world of plastic manufacturing, advanced injection mold design is an important factor that influences efficiency, costs, and product quality. Advanced designs can significantly reduce costs per part by incorporating strategies like the use of durable molds and designs with multiple cavities. This approach not only extends the mold’s operational life but also accelerates production speed by reducing cycle times, driving down costs and enhancing overall efficiency. 

Additionally, expert designs enhance process repeatability and contribute to a substantial return on investment and heightened productivity. The optimised design and material selection not only speed up the manufacturing process but can also ensure visually appealing products. 

Beyond aesthetics, durability is paramount in advanced mould design. The choice of materials and the thoughtful design of the mould directly impact the number of successful parts that can be manufactured. Furthermore, advanced designs contribute significantly to the durability of the produced parts, minimising breakage, and resulting in a superior product.

Choose Sustainable Plastic Materials and Practices 

In an era where sustainability is non-negotiable, sustainable injection moulding materials are game-changers for plastic manufacturing companies. These materials not only contribute to environmentally friendly practices but also respond to the growing demand for eco-conscious products.

The plastic industry is increasingly adopting recycling practices to further minimise its environmental footprint. Through practices such as closed-loop recycling systems and the utilisation of recycled plastics in the manufacturing process, plastic manufacturers are actively contributing to a more sustainable economy. This commitment not only reduces dependence on raw materials but also addresses the issue of plastic waste. By choosing plastic manufacturing services that prioritise sustainable materials, you align your projects with global efforts toward a greener future.

Opt for Ultrasonic Welding

The accuracy, energy efficiency and speed of ultrasonic welding make it a superior alternative to traditional bonding methods in plastic manufacturing processes. Ultrasonic welding uses ultrasonic vibrations to create precise and efficient bonds, eliminating the need for additional materials like adhesives or mechanical fasteners. The process is fast, energy-efficient, and results in seamless joints that enhance product quality and durability. Its applications span diverse industries, including automotive, electronics, medical devices, and packaging. From assembling automotive components to joining delicate electronics and sealing packaging materials, ultrasonic welding delivers unparalleled precision, making it a crucial advancement in industries where reliability and efficiency are paramount.

Choose Expert Plastic Manufacturers

Choosing the right plastic manufacturing company is a pivotal decision that can significantly enhance the plastic manufacturing process. A reliable and experienced company brings expertise in material selection, advanced technologies, and efficient production methods. This expertise ensures the use of high-quality materials, optimised manufacturing processes, and adherence to industry standards, which all result in superior products.

If you’re looking for expert injection moulders who can help you create exceptional plastic products, Fern Plastics is a leader in this field. For more information about our plastic injection moulding services, contact our team today.

When it comes to plastic moulded products, two main moulding methods are often discussed, plastic injection moulding and vacuum moulding. But what is the difference between plastic injection moulding and vacuum moulding? We go into the differences between the two plastic moulding types and more.

What is Plastic Injection Moulding?

Plastic injection moulding is the process of injecting molten plastic into a pre-designed mould in order to create a plastic moulded product. By injecting molten plastic into a mould at high pressure, the plastic is forced to fill the gaps in the mould and create the shape of the mould design. Once the plastic has cooled, the mould is opened and the plastic injected products are removed from the moulding machine. 

What Type of Products Are Made From Plastic Injection Moulding?

Plastic injected products can be found everywhere in the home and beyond. Plastic injection moulding is often used to produce items such as recycling bins, medical tools, car parts, toys and more with the ability to highly customise the plastic mould meaning that a wide range of intricate designs can be produced in numerous quantities.

What is Vacuum Moulding?

Vacuum moulding, also known as thermoforming, is a process during which a heated sheet of plastic is stretched over a vacuum forming tool in order to form a plastic part. The thermoforming plastic sheet forms the shape of the mould through a vacuum process and as the sheet cools it forms a hard shape before the moulding tool is removed.

Here’s how the thermoforming process works:

• Preparation – A flat sheet of thermoforming plastic is clamped into a frame. The type of plastic chosen depends on the specific requirements of the part being produced.
• Heating – The sheet is then heated until it becomes soft and pliable. The temperature and heating time vary depending on the material’s thickness and type.
• Moulding – After the thermoplastic sheet is heated to the desired temperature, it is quickly moved to the mould or tool.
• Thermoforming – Once the heated sheet is in position over the vacuum-forming tool, a vacuum is applied beneath the mould, which suctions the plastic sheet tightly against the mould’s surface. This forms the plastic into the shape of the mould. Any excess material is trimmed away.
• Cooling and Release – After the plastic has taken the shape of the mould, it is cooled. Once it has cooled and solidified, the vacuum is released and the formed plastic part can be removed from the mould.

What Type of Products Are Made From Vacuum Moulding?

Depending on the design of the plastic moulding, vacuum moulding can create a variety of designs and styles. Items such as plastic bathtubs, garden equipment and plastic utensils can be made using the vacuum moulding process.

Plastic Injection Moulding Vs Vacuum Moulding, Which is Best?

When it comes to plastic formed products, each technique is different. For tight tolerances, plastic injection moulding is often more suitable than vacuum forming whilst the plastic injection process can also often work out as cheaper than the vacuum moulding process, particularly for larger projects where a high volume of plastic injected products need to be formed. The process of vacuum forming is sometimes also less controlled than plastic injection moulding die to the heated plastic being stretched over a mould.

What are the Advantages of Injection Moulding Compared to Vacuum Moulding?

There are a few advantages to using plastic injection moulding when compared to vacuum moulding.

High precision and tight tolerances – Plastic injection moulding allows for the production of parts with extremely tight tolerances and high precision. This process is capable of producing complex, intricate parts with consistent wall thickness, intricate details and minimal variations. In contrast, vacuum forming may have some limitations in achieving the same level of precision due to the stretching of the heated plastic sheet over the mould.

Higher production volumes –  Injection moulding is better suited to high-volume production runs when compared to vacuum moulding. The cycle times in injection moulding are typically faster than vacuum forming, and the process can produce a large number of parts in a shorter period of time. This efficiency makes it more cost-effective for long production runs

Material selection – Plastic injection moulding allows for the use of a range of thermoplastic materials including high-performance engineering plastics like Acrylonitrile Butadiene Styrene (ABS), Nylon (PA) and Polycarbonate (PC). This means that injection-moulded parts can have superior properties such as heat resistance, greater strength, chemical resistance and more. Injection moulding is often chosen when the application demands specific material characteristics and performance.

Plastic Injection Moulding Specialists

As plastic injection moulding specialists, we offer a wide range of plastic injection moulding services to help bring your project to life. We have a number of years experience and have faced every challenge there is in terms of plastic injection moulds so are perfectly placed to answer any questions you may have.

Contact our team now on 01902 758282 to find out more about the range of plastic injection moulding services and related services we offer and talk to our specialists.

The plastic injection moulding process produces hundreds and thousands of products every single day. From large-scale production projects to smaller, more bespoke mouldings, plastic injection moulding can produce a wide variety of shapes, styles and finishes, all with perfect uniformity. Low injection moulding costs mean that extremely large quantities can be produced with little effort in a relatively short space of time. Here’s our guide to the cost-effectiveness of plastic injection moulding.

Is Plastic Injection Moulding Cost-Effective?

One of the most attractive elements of plastic injection moulding is that is it an extremely cost-effective plastic product production process. Huge amounts of product can be produced from just a single injection mould making it a time-efficient and cost-effective production process. Whilst the initial costs may seem higher than other plastic production methods, he ability to produce tens of thousands of parts from one tool means that plastic injection mould costs, in the long run, are extremely cost-effective, especially for larger-scale or repeat projects.

Creating the Right Mould for your Project

Whatever your project, the right plastic injection mould can help make it a success without the gruelling production process other types of product creation may involve. At Fern Plastic, we know what goes into creating the perfect mould for the plastic injection moulding process and know that the right mould can save time and resources on post-production adaptations later on down the line.

How Do We Save Money on Injection Moulding Costs?

Here at Fern Plastics, we have a number of years of experience creating high-quality plastic injection moulds and injection moulded parts. We like to think that our process has been streamlined to be as cost-effective and environmentally friendly as possible in order to pass on those benefits to our customers. Some of the ways to keep plastic injection moulding costs as low as possible whilst still maintaining ultra-high quality levels include things such as modifying and reusing moulds to improve their performance and continue creating brilliantly-bespoke plastic injection moulded products. We also aim to recycle and reuse the majority of our product waste in order to lessen the environmental impact of the injection moulding process.

Here’s an in-depth look at how injection moulding costs can be reduced.

Optimise The Design of Moulded Parts

Smart part design is one of the most impactful ways to reduce the cost of plastic injection molding. By working closely with experienced engineers, you can create parts that are easier to mould and reproduce. Not only does this demonstrate design best practices, but also improves product efficiency. This results in reduced material requirements and minimises the need for secondary processes. Consider design elements like uniform wall thickness and avoiding undercuts or other intricate features that may require complex tooling. With efficient part design, overall cycle times are reduced with fewer discarded parts which saves time and money.

Select The Right Injection Moulding Material

Choosing the right injection moulding material is vital for cost reduction. While high-performance resins may offer excellent properties, they can significantly increase production costs. Injection moulding specialists will evaluate the required properties of the part carefully and consider using alternative materials that meet the necessary specifications at a lower cost. Recycled plastics can also be a viable option for certain applications, which reduces both material expenses and the impact on the environment. 

Optimise Tooling Design and Maintenance

Investing in high-quality tooling ensures consistent part quality and extends tool life. While initial tooling costs might be higher, better-quality moulds can result in lower production costs in the long run. Regular maintenance of the moulds is essential to prevent part defects, downtime and costly repairs.

Utilise Multi-cavity Molds

Using multi cavity molds allows multiple parts to be simultaneously produced in each molding cycle. This approach significantly increases the efficiency of production while reducing cycle time and lowering the overall cost per part. However, it is essential to balance the savings with the maintenance requirements of complex multi cavity molds.

Minimise Post-Molding Operations

Reducing the need for post-molding operations can save both time and money. Creating parts that require minimal or no secondary processes such as additional surface finishing and trimming. Integrating features directly into the mould can eliminate the need for additional manufacturing steps.

Mould Design Modifications

Before production, it is worth closely analysing the structural requirements of moulded parts. By closely examining the part’s structure, areas that are critical for function and quality can be identified and other areas can be modified. For example, gussets or ribs can be used to enhance the structural integrity of the part, replacing a completely solid area. This not only simplifies production but can also reduce weight, making it cost-efficient for shipping, storage and delivery. Additionally, replacing solid areas with hollow sections where appropriate, reduces the amount of injection moulding material used in the process which can further reduce costs. However, it is important to ensure that the quality isn’t compromised by the modifications as any savings would be cancelled out by the costs associated with failed parts.

Collaborate with Expert Injection Moulders

Partnering with experienced injection moulders can provide valuable insights and cost-saving suggestions. Collaborate with an injection moulding company that has a proven track record of optimising injection moulding processes and can offer innovative solutions and value-added services to cut costs without compromising quality.

Looking for a Cost-Effective Plastic Injection Moulding Specialist?

Our team are experts in creating industry-leading plastic injection moulded products with a full-service process from design to production to ensure your product is exactly how you envisioned it. Contact our team now to find out more about our plastic injection moulding costs or any other questions you may have on the services we provide.

Countless objects around the world both inside and outside of the home are now made from plastic. However, plastic waste has become a huge problem for the planet with many non-recycled plastic products going to landfill. As producers of plastic injection moulded products, we answer questions such as can injection moulded plastic be recycled and what we are doing to help reduce plastic waste in the injection moulding industry.

Can Injection Moulded Plastic be Recycled?

When it comes to recycling your plastic moulded products, the good news is that most of the time, the plastic they are formed from can be recycled. At Fern Plastics, we ourselves recycle our plastic waste in a conscious effort to reduce the amount of plastic we dispose of. Plastic injection moulding uses molten plastic injected into pre-made moulds to form a finished plastic item. These injection moulded plastic products are used for everything from car parts to household items such as cutlery and toys, many of which will be recyclable. The plastic used in these injection mouldings and products made from recycled materials can be reused and reformed time and again to reduce waste.

Recycling plastic that has been injection moulded does not result in any loss of quality making it ideal for the rapid production of recycled plastic products on a large scale. As well as reducing waste going to landfill, recycling our plastic waste and reusing plastics within our process helps to reduce the amount of raw materials needed for plastic injection moulding, reducing pollution.

How Do You Reduce the Amount of Plastic Waste at Fern Plastics?

At Fern Plastics, we know how important it is to reduce the amount of plastic waste we produce. That’s why reuse and recycle up to 100% of our plastic and manufacturing waste to be used for future projects without compromising on quality. We also recycle the plastic bags our raw material is supplied in and use in-house robots and granulators to recycle plastic waste. Our state of the art machinery ensures that every piece of plastic we use for our injection mouldings is used to its full capacity whilst our partners Recycled UK then re-process any plastic we cannot use for other non-technical markets. Manufacturing with recycled materials and recycling our plastic waste helps us to reduce the amount lost in our plastic injection moulding processes.

You can find out more about how we reduce plastic waste in our blog.

Plastic Injection Moulded Products from Fern Plastics

Here at Fern Plastics, we are industry leaders when it comes to plastic injection mouldings and injection moulded parts. We work closely with suppliers and clients to ensure our production perfectly fits their needs with in-house designers perfecting the plastic injection moulding process. We frequently use recycled plastics and recycled polymers such as recycled ABS in our moulding process to avoid waste at every stage of the process and create a more sustainable business model for our recycled plastic injection mouldings.

To find out more about our plastic injection moulding service and how we create an efficient, high-quality plastic injection moulding process, contact our team now online or by calling 01902 758282.

Plastic injection moulding is one of the most efficient and cost-friendly plastic product production processes. Countless household and business products are formed from plastic injection moulding, perhaps even items you didn’t think were injection moulded. We talk through why plastic injection moulding is so effective.

What is the Plastic Injection Process?

Plastic injection moulding is conducted through precisely injecting molten plastic at pressure into a specially-designed mould. Once the molten plastic cools, a firm product is produced that can stand the test of time. Over moulding and other processes can be used to create more bespoke, intricate plastic injection moulded designs that work for a variety of purposes.

Why is Plastic Injection Moulding So Effective?

Fewer plastic production processes are as effective as plastic injection moulding. One of the main reasons for this is the impressive cost-effectiveness plastic injection moulding enjoys. Injection moulding can produce high volumes of identical products with ease and with a much quicker turnaround than other plastic moulding processes. The efficiency of the injection moulding process is also a factor in the fantastic cost-effectiveness of plastic injection moulding. Once the specialised injection mould has been designed and created by our in-house experts, that same mould can be used countless times, producing plastic injected products with ease at very little cost per item.

Fast, Efficient Plastic Injection Moulding

Our state-of-the-art plastic injection moulding machines work round the clock to ensure high-speed plastic product production that doesn’t compromise on quality or design. The efficiency of custom plastic mouldings results in low labour costs and lower end costs with the ability to use multiple types of plastic within the injection moulded products.

Strong, Fit-for-Purpose Design

The nature of the plastic injection moulding process makes it ideally adaptable for all manner of purposes. From household objects to car parts to medical equipment, plastic injection moulded products can be designed with a number of parts and features to fit a range of uses. Multiple type of plastic can be combined within the injection moulding to form a bespoke product with intricate details and complex shapes repeated time and again for each and every plastic injection moulded product. The ability to create custom plastic mouldings with ease is one of the ways plastic injection moulding is so effective.

Plastic Injection Moulding Specialists

When it comes to ensuring an effective plastic injection moulding process, Fern Plastics are leaders in their industry. Crafting bespoke plastic mouldings using time-honed skills and state-of-the-art technology Fern Plastics can create intricate designs and parts with extremely close consistencies. To find out more about our plastic injection services, contact our team now on 01902 758282.